TM 9-787A
WAR DEPARTMENT
TECHNICAL MANUAL
HEAVY TRACTOR Ml
(ALUS-CHALMERS HD-lOW)
DECEMBER 21, 1942
TM 9-787A
.tHNICAl MANUAL WAR DEPARTMENT
No. 9-787A Washington, December 21, 1942
HEAVY TRACTOR Ml
(AlllS-CHAlMERS HD-10W)
Prepared under the direction of the
Chief of Ordnance
(with the cooperation of the Allit-Chalmeri Manufoeturing Company)
Pages
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16
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41
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48
49
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52
53-
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CONTENTS
PART ONE— Operating Instructions
Paragraphs
Section I. Introduction 1— 3
II. Description and tabulated data . 4— 5
III. Operating instructions and con-
trols 6-26
IV. Lubrication 27—32
V. Preventive maintenance 33— 42
VI. General care and ^preservation . 43— 44
VII. Painting 45-50
VIII. Materiel affected by gas 51-54
PART TWO— Organization instructions
IX. General information on mainte-
nance 55 5j§^ 58
X. Standard tools and equipment. 56- S? 59^7 61
XI. Engine 58-64' 62-90
XII. Fuel and air system 65- 73 91-123"
XIII. Cooling system '74- 89 - 124-138
XIV. Lubrication system 81-84 139-146
XV. Electrical system and equipment 85- 96 147-180
XVI. Nonelectrical instruments .... 97-101 181-186
XVII. Electric and air trailer brake
control system 102-104 187-197
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Paragraphs Pages
Section XVIII. IVIaster clutch and clutch brake 105-109 , 198-203
XIX. Steering clutches 110-113 204-208
XX. Tractor brakes 114-115 209-211
XXI. Final drives 116-118 212-214
XXII. Tracks and truck frame assem-
bly 119-123 215-225
XXIII. Winch and power take-off 124-125 226-229.
XXIV. Storage and shipment 126-132 230-241
XXV. Cold weather lubrication and
service 133-138 242-246
XXVI. References 139-140 247-248
Index 249-257
HEAVY TRACTOR Ml
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PART ONE— Operating Instructions
Section I
INTRODUCTION
Paragraph
Purpose and scope 1
Content and arrangement o'f manual 2
References 3
1. PURPOSE AND SCOPE.
a. The information and instructions contained in this manual provide
a guide for all personnel charged with the operation, lubrication, and
light maintenance of this materiel. Specifications, illustrations, and de-
tailed instructions are given regarding the operation, lubrication, adjust-
ments, and minor repairs. Group assemblies and component parts are
listed under separate headings, with detailed instructions under each
heading explaining the proper operation or adjustments necessary to
keep or put the machine in normal operating condition.
2. CONTENT AND ARRANGEMENT OF MANUAL.
a. Part One consists of specifications and photographs of the tractor,
lubrication charts and specifications, and general operating instructions.
Part Two consists of illustrations and instructions on adjustments and
minor repairs.
3. REFERENCES.
a. A list of references will be found in section XXVI of this manual.
TM 9-787A
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INTRODUCTION
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INTRODUCTION
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Section II
DESCRIPTION AND TABULATED DATA
Parograph
Description 4
Tabulated data 5
4. DESCRIPTION.
a. General. This tractor is of the crawler or track-laying type and
may be used for either highway or cross country travel. Because of its
relatively low center of gravity, the tractor can climb slopes as steep as
30 degrees, depending on the kind of footing available and the load being
pulled.
b. Engine. Power is supplied by a water-cooled, 4-cylinder, valve-
in-head, 2-cycle Diesel engine. A multiple speed transmission is used offer-
ing six forward speeds ranging from 1.87 miles per hour to 11.00 miles
per hour and two reverse speeds of 2.05 miles per hour and 4.60 miles per
hour at full throttle engine speed. The fuel tank has a capacity of 156 gal-
lons which permits about 20 hours of operation without refueling.
c. Steering. Steering is accomplished by means of steering clutches
operated by two levers, mounted in the center of the tractor within easy
reach of the operator. Each lever controls a multiple disk steering clutch
through which power is delivered from the transmission to the final drive
sprockets.
d. Seat. The seat has removable cushions and safety straps and will
accommodate the operator and three other men.
e. Winch. The winch is mounted on the front of the tractor and is
driven by a reversible power take-off from the tractor transmission. A con-
trol lever for the power take-off is just ahead of the seat and in easy reach
of the operator.
f. Equipment. Equipment on the tractor includes batteries, electric
starter, generator, lights, mile meter, engine air heater and engine pre-
heater for cold weather starting, fire extinguisher, electric and air trailer
brake control system, snatch block, tow chain, and loose tools.
g. Tractor and Engine Numbers. The serial number of the tractor
is stamped on the steering clutch lever stop which is on the gear shifter
housing and also on the rear of the transmission case on the right side
just below the top. The engine number can be found on a bronze plate on
the right side of the engine in back of the governor.
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DESCRIPTION AND TABULATED DATA
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DESCRIPTION AND TABULATED DATA
RA PD 17207
Figure 6— Heavy Tractor Ml —Top View
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figure 7— Heavy Tractor fAI —Front View
5. TABULATED DATA.
a. General.
Maximum drawbar horsepower:
At 2,000 rpm (full throttle) 88.5
At 1,750 rpm (throttle in stop notch) 84.2
Maximum drawbar pull:
At 2,000 rpm (full throttle) 18,350 lb
At 1,750 rpm (throttle in stop notch) 20,120 lb
Shipping weight (approx.) 25,500 lb
b. Dimensions.
Over-all length 14 ft 5 Va in.
Over-all width 8 ft 1 in.
Over-all height 8 ft 4 in.
Tread width (center to center of tracks) , 6 ft 2 in.
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DESCRIPTION AND TABULATED DATA
RA PD 17209
Figure 8— Heavy Tractor Ml —Rear View
Ground clearance 12 in.
Height of lower pintle 2 1 % in.
Height of upper pintle 34 Vi in.
Lateral movement of drawbar 32 in.
Turning radius '. 10 ft 10 in.
c. Performance.
Speeds and drawbar pull:
At 2,000 rpm (full throttle)
First gear ( 1.87 mph) 18,350 lb
Second gear (2.98 mph) 10,950 lb
Third gear (4.21 mph) 7,160 lb
Fourth gear (4.88 mph) 5,860 lb
Fifth gear (6.72 mph) 3,560 lb
Sixth gear (11.00 mph) 1,120 lb
Low reverse gear (2.05 mph)
High reverse gear (4.60 mph)
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At 1,750 rpm (throttle in stop notch)
First gear ( 1.63 mph) 20,120 lb
Second gear (2.60 mph) 12,170 lb
Third gear (3.68 mph) 8,080 lb
Fourth gear (4.27 mph) 6,680 lb
Fifth gear (5.88 mph) 4,230 lb
Sixth gear (9.62 mph) 1,590 lb
Low reverse (1.80 mph)
High reverse (4.02 mph)
Maximum trench crossing (estimated) 3 ft
Maximum fording depth (at minimum speed):
Without drain plugs in master clutch and steering clutch
compartments 2 1 in.
With drain plugs in master clutch and steering clutch com-
partments 4 1 Vi in.
Maximum grade ascending ability (estimated) 30 deg
Maximum grade descending ability (estimated) 30 deg
Allowable list (side slope) (estimated) 30 deg
Maximum vertical obstacle 221/2 in.
d. Engine (General Motors 4-71 RC14).
Number of cylinders 4
Firing order 1-3-4-2
Bore and stroke 4 Vi in. x 5 in.
Piston displacement 284 cu in.
Rated speed (at full throttle) 2,000 rpm
Rated speed (throttle in stop notch) 1,750 rpm
Revolutions per minute (at maximum torque) 800—1,200
e. Steering.
Method Clutches
Number of friction surfaces (each clutch) 30
Total area of friction surfaces (each clutch) 1516.5 sq in.
f. Tracks.
Length of track on ground 6 ft 5 % 2 in-
Ground contact area (each track) 1,542 sq in.
Width of shoes 20 in.
Grouser height 2 in.
Number of track shoe bolts (per shoe) 4
Diameter of track shoe bolts 2 1^ ^ in.
Diameter of track pins 1% in.
Diameter of track pin bushings 2 Va in.
Number of shoes per track 32
Ground pressure (approx.) 8.27 lb per sq in.
Type of bearings in truck wheels and idlers Tapered roller
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DESCRIPTION AND TABULATED DATA
RA PD 17210
figure 9— Heavy Tractor Ml —Bottom View
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g. Winch.
Length of drum 22% in.
Diameter of drum 7 in.
Length of cable 300 ft
Diameter of cable % in.
Maximum cable speed (bare drum) 33 ft per min
Maximum pull 30,000 lb
h. Power Take-Off.
Rpm at rated engine speed (max) 540
i. Capacities.
Fuel tank 156 gal
Engine crankcase SVk gal
Air compressor crankcase % qt ■
Cooling system 9% gal
Transmission case 6 gal
Final drive case ' 2 gal
Track release spring housing , 1 ys gal
Winch gear housing 1 gal
Power take-off housing 2 Vs gal
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TM 9-787A
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Section III
OPERATING INSTRUCTIONS AND CONTROLS
Poragraph
Inspection of new tractor 6
Prepare new tractor for use 7
Prepare new batteries for use 8
Operation of new tractor 9
Engine starting instructions (temperature normal) 10
Engine starting instructions (temperature 40 F to F) 11
Engine starting instructions (temperature below OF) 12
Stop engine ^ 13
Use of master clutch 14
Transmission IS
Steering 16
Steering clutch brakes 17
Steering down hill 18
Operating in abnormal conditions ' 19
Use of winch and controls 20
Power take-off 21
Use of trailer brakes 22
Parking vehicles 23
Lighting system 24
Hour meter 25
Mile meter 26
6. INSPECTION OF NEW TRACTOR.
a. Make a complete inspection for any shortage or damage which may
have occurred while in transit or in storage.
7. PREPARE NEW TRACTOR FOR USE.
a. Remove the air cleaner oil bath cups to make sure they contain the
correct amount and grade of oil (par. 73).
b. Inspect the oil level in the engine crankcase, air compressor crank-
case, transmission case, final drive gear cases, track release spring hous-
ings, winch gear housing, and the power take-off housing.
c. Lubricate all other parts of the tractor in accordance with instruc-
tions in section IV. The truck wheels, track support rollers, and front
idlers must be filled by means of a special flushing lubricator supplied
with the tractor. These rollers have been filled with oil at the factory,
but before tractor is put into operation they should be thoroughly flushed
and refilled to remove any metal particles which might remain from
manufacturing operation and have loosened during shipment.
NOTE: All lubrication points are painted red.
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HEAVY TRACTOR Ml
d. Check and fill fuel tank with the correct fuel oil. Special care must
be taken to prevent the entrance of dirt or foreign materials while filling
the tank.
e. Fill the cooling system with clean water. CAUTION: Remove the
pipe plug (fig. 28) in the thermostat housing while filling cooling system.
This allows the air to pass out of motor block while water is put in.
Replace the plug when water runs out of the hole and finish filling. In
winter weather, use a standard antifreeze solution in the cooling system.
The solution should be tested daily and kept to the proper strength for
the prevailing temperatures. The antifreeze used should have a higher
boiling point than the engine operating temperature (160 F to 180 F).
8. PREPARE NEW BATTERIES FOR USE.
a. The batteries shipped with the tractdr contain dry charged plates
but no electrolyte. Vent plugs are screwed in tight and must remain so
until the cells are filled with electroljrte. Keep vent plugs and sealing disks
tight until ready to prepare battery for service; then discard disks.
(1) Remove sealing disks, located on top or under vent plugs, and
make certain vent hbles in all plugs are open.
(2) Fill cells to Ys inch above separators with electrolyte not warmer
than 70 F. (Electrolyte is furnished with tractor.)
(3) Let battery stand one hour; then, if liquid level has fallen, add
electrolyte to restore level. Screw vent plugs in place. Wipe off any
spillage.
(4) Charge battery 16 to 20 hours at 14 amperes before placing in
service. Use series charging (never constant potential) for this initial
charging.
9. OPERATION OF NEW TRACTOR.
a. Operate a new tractor with a light load during the first 60 hours.
After the first 10 hours of operation, the tractor should be stopped and
inspected for loose bolts and nuts. The stearing clutch and the master
clutch adjustments should be checked (pars. 108 and 112).
10. ENGINE STARTING INSTRUCTIONS (Temperature Normal).
a. Figure 10 shows the operating controls and instruments.
b. Each time before starting engine, the operator should make a
prestarting inspection (par. 34). Then proceed as follows:
( 1 ) Close radiator shutter by pulling on shutter control lever.
(2) Push engine shut-off control forward.
(3) Open throttle lever to stop notch.
CAUTION : See that master clutch and power take-off are disengaged
and gear shift lever is in neutral position.
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OPERATING INSTRUCTIONS AND CONTROLS
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(4) Push starter pedal. As soon as engine fires and begins to run, close
throttle to about three-quarter engine speed and allow engine to warm up.
When engine temperature reaches 160 F, open radiator shutter; shutter
should be adjusted so that an operating temp)erature of 160 F to 180 F is
maintained at all times.
(5) Check lubricating oil pressure. Oil pressure should be between
25 and 35 on the gage with engine running at full governed speed and
heated to normal operating temperature. Pressure may drop to five on the
gage when engine is idling. If the oil is cold, no pressure may register for
about 15 seconds after the engine starts. If the pressure does not rise
to between 25 and 35 under hormal operating conditions, the engine
should be stopped and the cause determined.
(6) Check fuel oil pressure. Fuel pressure at full governed engine
speed should be from 20 to 30 on the gage. Operate throttle to meet
various operating conditions.
11. ENGINE STARTING INSTRUCTIONS (TEMPERATURE
40F to OF).
a. Engine can be started in temperatures of zero or a little below by
using the air heater, if engine and batteries are in good condition and
lubricating oil used is of the proper viscosity.
b. Operation of Air Heater.
( 1 ) Close radiator shutter by pulley and shutter control.
(2) Push engine shut-ofif knob to its "IN" position and open throttle
lever to stop notch.
(3) Release air heater fuel pump plunger by turning one-quarter to
one-half turn counterclockwise.
(4) Close air heater switch by pressing on the button at left side of
dash, engage starter, and operate pump with smooth even strokes.
NOTE: These three operations must be performed simultaneously. By
doing this, practically all fuel pumped through the air heater will be
burned, reducing collection of raw fuel in the air box to a minimum. If
the starter is not used with the air heater, oxygen in the engine will soon
be exhausted; then the flame will go out and raw fuel will be pumped
into the engine. The air heater should be operated for a short period
after engine starts; to keep the engine operating smoothly.
(5) Check lubricating oil pressure (par. 10).
(6) Check fuel oil pressure. Fuel pressure at full governed engine
speed should be from 20 to 30 on the gage. Operate throttle to meet
various operating conditions.
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OPERATING INSTRUCTIONS AND CONTROLS
12, ENGINE STARTING INSTRUCTIONS (TEMPERATURE BE-
LOW F).
a. In temperatures below zero, it may be necessary to use the engine
preheater (figs. 11, 12, and 13).
b. Install preheater intake assembly on engine in place of one of the
air box inspection covers, if this has not been done previously. This
intake elbow is divided into two parts by a baffle. The heater extension
tube will fit into upper part. The lower opening is for exhaust of heater
gases after circulation through the air box.
c. Operation of Engine Preheater.
(1) Remove filler plug and fill case about two-thirds full of fuel oil,
the same as is used in the fuel tank of the tractor.
(2) Replace filler plug securely to prevent leakage.
(3) Close needle valve.
(4) Pump up to about 120 pounds pressure with hand pump.
(5) Close air regulator plate next to preheater fan.
(6) Plug preheater fan wire into the socket on front of cowl which is
directly connected to the battery. The heater fan should start imme-
diately and rim as long as the connection is maintained.
(7) Separate heater from extension tube; then open needle valve
until a good spray or mist is ejected. Ignite spray with a -match or other
means; then place heater on extension tube.
(8) Loosen wing nuts on the top of intake elbow and open cover.
Place end of preheater extension tube into intake elbow. Open air regu-
lator plate. Preheater will blow hot gases into engine air box and will
circulate them around all cylinders. For the proper length of time to
leave preheater on, refer to the following chart:
Atmospheric Temperature Preheater On
OF 10 to 15 minutes
— 10 F 10 to 15 minutes
— 20 F 10 to 20 minutes
— 30 F 15 to 20 minutes
— 40 F 15 to 30 minutes
(9) After preheater has been in operation for the proper length of
time, remove it; close needle valve and air regulator plate; remove plug
from socket; close cover on intake elbow and fasten it securely. Start
the engine immediately, using the engine air heater, as when starting in
mild cold weather conditions. CAUTION: Do not attempt to start the
engine until the engine preheater has been removed and the intake
cover has been securely replaced.
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OPERATING INSTRUCTIONS AND CONTROLS
RA PD 1770T
Figure 12— Engine Preheater
RA PD 17662
Figure 13— Igniting Pretieater Spray
d. The engine preheater is used to warm up engine for easy crank-
ing only and will not aid combustion by furnishing warm air to the
cylinders. For this reason, it is necessary to use the engine air heater, as
this unit heats the cold air before it is drawn into the combustion chamber.
e. Place preheater back in box on tractor.
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HEAVY TRACTOR Ml
13. STOP ENGINE.
a. Close the throttle lever and pull engine shut-off knob all the way
out.
14. USE OF MASTER CLUTCH.
a. When the correct gears are engaged, open the throttle and pull
back steadily on master clutch lever until all slack is taken up between
tractor and load; then, pull lever back quickly to full extent to lock
clutch in its engaged position.
b. Do not slip the master clutch in an effort to pull an overload at
high speeds. Avoid excessive wear on the clutch disk facings by shifting
to a lower speed when necessary. Do not let engine idle with master
clutch disengaged. When engine is idling, shift gears into neutral and
engage master clutch.
15. TRANSMISSION.
a. Description. The transmission has six forward and two reverse
speeds. The high and low range make possible this variety of speeds.
b. Care. The transmission requires Jittle attention other than main-
taining proper oil level. Lubrication instructions are covered in section
IV. The transmission case should be washed with OIL, engine, SAE 10,
at the time the oil is changed. Fill to the proper level with OIL, engine,
SAE 10. Operate the tractor in low gear first for a few minutes. Drain
and lubricate.
c. Use of Gear Shift Levers (figs. 14 and 15). Two levers are used
to shift the gears. The left lever (looking forward) is an auxiliary lever
for shifting the auxiliary gears and has two positions, indirect (forward)
and direct (backward). The right lever is the gear shift lever and has
four positions. When the auxiliary gear shift lever is in the direct (back)
position the tractor can be run in third, fifth, sixth, and high reverse;
when in indirect (forward) position the tractor can be run in first, second,
fourth, and low reverse.
d. The following chart shows the position of the two gear shift levers
to obtain any of the six forward and two reverse speeds:
Gear Gear Shift Lever Auxiliary Shift 1-ever
First Left and back Forward (indirect)
Second Right and forward Forward (indirect)
Third Left and back Back (direct)
Fourth Left and forward Forward (indirect)
Fifth Right and forward Back (direct)
Sixth Left and forward Back (direct)
Low reverse Right and back Forward (indirect)
High reverse Right and back Back (direct)
Once a speed has been selected and the tractor is in operation, further
gear shifting cannot be done until the clutch has been disengaged and the
tractor stopped.
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OPERATING INSTRUCTIONS AND CONTROLS
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RA PD 17213
Figure 14— Gear Shift Instruction Plate
FOURTH INDIRECT
SIXTH DIRECT
FIRST INDIRECT
THIRD DIRECT
INDIRECT
DIRECT
AUXILIARY GEAR
SHIFT LEVER
SECOND INDIRECT
FIFTH DIRECT
low REVERSE INDIRECT
IGH REVERSE DIRECT
GEAR SHIFT
LEVER
RA PD 53977
Figure IS— Gear Shift Lever Positions
e. To shift gears, push master clutch lever forward and shift gears to
the desired speed. When the master clutch lever is pushed forward, it
forces the release bearing carrier against the clutch brake assembly fas-
tened to the clutch shaft, thus bringing the transmission gears to a rapid
stop. This quick stopping of the gears enables the operator to shift with-
out clashing the gears.
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16. STEERING.
a. Steering the tractor is accomplished by the use of steering clutches
which are operated by steering levers to disconnect power from either
track. Turn the tractor in the desired direction by pulling back to the
full extent the steering lever on the side toward-which the turn is to be
made. This disengages the clutch on that side and should be done
quickly and evenly to avoid excessive clutch wear. CAUTION: Do not
release the levers and let them fly forward. Do not operate tractor with
steering clutches partially disengaged. Avoid excessive wear of the steer-
ing clutches by releasing and engaging the steering clutches smoothly
and completely.
17. STEERING CLUTCH BRAKES.
a. The steering clutch brakes are for retarding the speed or holding
the track on the inside of the turn stationary when the steering clutch on
that side is released for making the turn. Always release the steerjng
clutch before depressing the brake when making a turn. The steering
brakes are also used as service brakes for retarding the speed of the
tractor when going down grade and to hold the tractor stationary.
18. STEERING DOWN HILL.
a. In steering the tractor down steep grades with the load pushing
the tractor, the use of the steering clutches is opposite to that of a tractor
pulling a load. If it is desired to make a turn toward the right, the left
steering clutch should be released. The engine, being connected to the
right track, acts as a brake retarding its progress, while the left track
is released and free to travel faster.
b. If a shorter turn is desired when the load is pushing the tractor,
apply the brake on the side opposite the side on which the clutch is
released.
19. OPERATING IN ABNORMAL CONDITIONS.
a. The master clutch and steering clutch compartments are dry
compartments and are provided with drain holes to drain out any oil
that might leak into the compartments by overlubrication or other
causes (fig. 9). In normal operation, these holes are to be left open.
When operating in mud, water, or extreme dusty or sandy conditions
the plugs provided with the tractor should be installed in these drain
holes to prevent the entrance of dirt or water. The plugs should be
removed daily to allow any oil or grease that might accumulate in the
compartments to drain out, preventing it from getting on the brake
bands or clutch facings. If the tractor is idle at night, the plugs may, be
removed to drain the compartments, then replaced in the morning.
Inspect the final drives frequently and drain, wash, and refill the case
as often as the lubricant shows the presence of any mud or water.
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OPERATING INSTRUCTIONS AND CONTROLS
20. USE OF WINCH AND CONTROLS.
a. To Engage the Winch. Before operating the winch, the engine
must be idhng and the tractor stopped, with the engine clutch disen-
gaged. Then, pull the power take-off shifter lever back until the lock on
the lever engages in the front notch (unwinding position for uiireeling
cable from drum). Release the winch brake, engage the master clutch,
and the cable will unreel from the drum. Unreel just enough cable so
that the hook can be attached to the load and disengage the master
clutch.
b. To pull load after cable is attached, push power take-off shifter
lever ahead until lock catches in rear notch (winding position). Set the
foot brakes by pushing the brake pedals down hard and lock them by
lifting up on brake pedal lever locks. Engage master clutch and cable
will wind up and pull load. NOTE: Winch can be operated in either
of two speeds by shifting the tractor auxiliary gear shift lever. Direct
position gives the highest winch speed. In indirect position, the winch
runs at 44 percent of the speed when in direct position and gives a corre-
sponding increase in winch pull. Use caution in engaging load to pre-
vent cable breakage or excessive strain on winch. Always try to keep
cable wound evenly and smoothly on the drum. Stop winch by disen-
gaging master clutch. If load is to be moved a little at a time, cable
will be held taut when master clutch is disengaged by the automatic
safety brake on the winch worm shaft. If cable is tight when pull is com-
pleted, move tractor ahead to relieve strain so cable may be released.
Wind cable up, release jaw clutch and pull power take-off shifter lever
into neutral position (lock in middle notch). Set winch hand brake
by pushing inside lever on fender forward. CAUTION: Never pull
out winch jaw clutch when winch is under load.
c. The winch hand brake is used only to control the drum when
reeling off cable by hand or if another machine is pulling on the cable
to unreel it. CAUTION: Be sure jaw clutch is disengaged if cable is
unreeled in this way.
21. POWER TAKE-OFF.
a. Bearings on the upper power take-off shaft are splash-lubricated,
and if the tractor is used with the power take-off disengaged, these bear-
ings will receive no lubrication. Therefore, while the tractor is running,
the power take-off should be engaged once a day and run a few min-
utes in order to lubricate these bearings. CAUTION: Make sure that
this is done to prevent these bearings from running dry and freezing.
22. USE OF TRAILER BRAKES.
a. Brakes on a trailer pulled by the tractor may be operated either
by air or by electricity (depending on the type of brakes mounted on
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HEAVY TRACTOR Ml
the trailing unit) since the tractor is equipped with complete controls
and operating mechanism for both air brakes and electric brakes. Trailer
brakes operate only on the load behind the tractor and are not effective
in stopping the tractor itself.
b. The trailer brakes have two controls. The hand grip on the right
steering clutch lever (fig. 10), when compressed, operates either the air
or the electric brakes, while the hand control on the right of dash is
used for operating the air brakes only. Only one system is used at a
time, depending on whether drawn vehicle is equipped with air or elec-
tric brakes.
c. Connections.
(1) Two air hose couplings are provided for connecting trailer air
brake hoses. The one on the left is marked "SERVICE" and the one on
the right "EMERGENCY." The corresponding hoses on the trailer
should be connected to these couplings. When tractor is operating with-
out trailer, valves should be closed and the dummy couplings hanging
on tractor should be installed to keep dirt and dust out of system.
(2) The rear coupling socket on the tractor is wired so that when
the plug from a trailer vehicle equipped with electric brakes is inserted,
all electric brake and light apparatus will operate properly from tractor
light switches and brake controls.
d. Operation of Electric Brakes. The brakes should be operated
according to the requirements of the trailer. If a light braking effect is
desired, the electric brake load control at the right of dash may be set
accordingly. Turning knob to left (counterclockwise) gives a lighter
braking effect, and turning knob to right increases braking power. The
brake can be applied only by squeezing grip on right steering clutch
lever. Trailer stop light goes on automatically.
e. Operation of Air Brakes. The air brakes can be applied either
by squeezing the steering lever grip or by moving hand air brake con-
trol at right of dash to the right. Use air brakes lightly by moving air
brake control lever clear to right and back halfway quickly. Repeat
this action until stop is made. This causes brake shoes to be applied
repeatedly against brake drums without locking and sliding wheels.
When it is necessary to stop the vehicle as quickly as possible, the
operator can lock the wheels by holding the lever all the way to the
right until the stop is made. The steering lever grip is operated in the
same manner if this brake control is used.
f. The master clutch of the tractor should be disengaged and tractor
brakes applied whenever trailer brakes are used. Care should be taken
that trailer and tractor brakes are applied evenly and at the same time
to prevent jackknifing of the tractor and trailer unit.
28
TM 9-787A
23-25
OPERATING INSTRUCTIONS AND CONTROLS
23. PARKING VEHICLES.
a. If tractor and trailer are to be parked, especially on a slope where
there is a possibility of rolling, the tractor foot brakes should be set by
depressing pedals as far down as possible and lifting brake pedal lever
locks to lock them in position.
24. LIGHTING SYSTEM.
a. The lighting control system on the tractor is designed to operate
both the lights on the trailed vehicle and those on the tractor. Proper
connections are located at the rear of the tractor.
b. Light Switches. The light switch at left of dash has three posi-
tions for turning on the various lights. When the knob is pulled out to
the first stop, only the blackout lights are turned on. For regular service
lights, the small button on the top of the switch must be pressed down
and knob pulled out to the second stop. To use the stop light only, for
day driving, press top button and pull knob full out. This light goes on
automatically when the master clutch lever is pushed forward to dis-
engage clutch.
c. The panel light is turned on by pulling out knob marked
"PANEL LIGHT." This will not function unless other lights have been
turned on also.
d. Turn off all lights by pushing knobs all the way in.
25. HOUR METER (fig. 16).
a. Description. This meter is electrically operated. A small auto-
matic pressure switch is closed by oil pressure as soon as the engine is
started and the oil pressure reaches five pounds. The small hand at the
top left of the dial will then start rotating. This hand indicates that the
meter is operating.
b. How to Read Hour Meter.
(1) The three hands in the center of the dial record the number of
hours the tractor has operated and are of three different lengths. Total
hours is determined by reading the number each hand has passed, the
same as we look at a clock to see which number the hour hand, the
minute hand, and the second hand have passed, and thereby tell the
time.
(2) The shortest hand requires 1,000 hours of operation for it to
pass each numeral, or 10,000 for a complete revolution. It stands be-
tween 2 and 3 which indicates over 2,000 hours of operation (fig. 16).
This indicates that the first numeral in the number of hours operated
29
TM 9-787A
25
HEAVY TRACTOR Ml
RA PD I72I4
figure 16— Hour Meter
will be 2, followed by three other numerals indicated by the position
of the other two hands, which in turn show how many hours more than
2,000 that the tractor has operated.
(3) The middle length hand requires 100 hours of operation for it
to pass each numeral, or 1,000 hours for a complete revolution. In
figure 16 it stands between 3 and 4, which indicates over 300 hours
that must be added to the 2,000. The second numeral then will be 3.
Now observe the position of the longest hand to determine in the same
manner how many hours must be added to the 2,300 indicated by the
other two hands.
(4) This longest hand requires 1 hour of operation for it to pass
each mark on the outer circle, 10 hours to pass each numeral or 100
hours for a complete revolution. Here it stands on the second mark past
9, which indicates 92 hours to be added to the 2,300 so that the correct
meter reading is 2,392.
c. The small hand at top left of dial will continue to rotate for
approximately a minute after engine is stopped, or until oil pressure
drops below five pounds.
30
TM 9.787A
26
OPERATING INSTRUCTIONS AND CONTROLS
26. MILE METER.
a. Description. This meter is located at the left side of the dash and
distances traveled should be entered in log book for record purposes.
The mile meter is driven by a flexible cable extending from the back
of meter into the transmission case to a spur gear driven by a worm
gear on the front end of the lower transmission shaft.
b. How to Read Mile Meter. Refer to paragraph 25 b on reading
of hour meter. The mile meter should be read in the sarrie manner as
the hour meter, except that miles will be noted instead of hours.
31
TM 9.787A
27-29
HEAVY TRACTOR Ml
Section IV
LUBRICATION
Paragraph
General 27
Lubrication guide 28
Detailed lubrication and service instructions for using arms. ... 29
'Points to be lubricated by ordnance maintenance personnel .... 30
Reports and records 31
Supplementary lubrication illustrations 32
27. GENERAL.
a. The following lubrication instructions for the Heavy Tractor Ml,
Allis-Chalmers HD-lOW, are published for the information and guidance
of all concerned, and supersede all previous instructions.
b. References, Materiel must be lubricated in accordance with the
latest instructions contained in technical manuals and/or ordnance field
service bulletins.
28. LUBRICATION GUIDE.
a. Lubrication instructions for all points to be serviced by the using
arms are shown in the lubrication guide (figs. 17 and 18) which specifies
the types of lubricants required and the intervals at which they are to
be applied.
29. DETAILED LUBRICATION AND SERVICE INSTRUCTIONS
FOR USING ARMS.
a. Air Cleaner. Proper maintenance of air cleaner is essential to
prolonged engine life. Service air cleaner as indicated on lubrication
guide.
b. Fuel Filters. When elements become plugged, replace with new
elements. Do not attempt to wash old elements. The average period
of replacement is 400 hours, or until drop in fuel pressure is noted.
Service fuel filters, as indicated in note 9 of lubrication guide.
c. Oil Filter. Earlier models have two oil filters. Later models have
only one.
( 1 ) The filter common to all models is on the right-hand side of the
engine and should be serviced as follows:
(a) Remove drain plug from filter adapter and drain filter housing.
(b} Remove stud from top of filter housing and lift ofT housing.
Remove filter element.
32
TM 9-787A
29
LUBRICATION
(c) Wash element in Diesel fuel. Scrub with soft brush. Do not
scrape with sharp instrument or wire brush, as damage may result.
(d) Clean filter housing and adapter. Reassemble filter.
(2) The second oil filter, used only in earlier models, should be
serviced as follows:
(a) Remove filter element every 240 hours of operation.
(b) Wash filter base and shell. Install new element.
■d. Generator. The two hinged cap oilers should be lubricated
sparingly with OIL, engine, crankcase grade, every 64 hours of opera-
tion. Do not oil excessively. CAUTION : Never oil commutator.
e. Final Drive. Service final drive as indicated in lubrication guide.
Magnetic drain plug is designed to catch all iron particles that might
chip or wear off during operation. This plug should be cleaned and
magnetism tested each time it is removed to drain final drive case.
f . Steering Clutches and Master Clutch, Washing of clutch units
about every 240 hours is essential to efficient operation. Wash each
clutch as follows:
( 1 ) Lubricate throwout bearings.
(2) Install plug in drain hole of steering clutch compartment.
(3) Fill compartment with 5 gallons of Diesel fuel or SOLVENT,
dry-cleaning, bringing level to about 4 inches below the steering clutch
shaft.
(4) Start engine and move tractor for several minutes without re-
leasing steering clutches. Stop tractor and drain compartment.
(5) Replace .plugs and fill with the same amount of Diesel fuel or
SOLVENT, dry-cleaning. Operate tractor with no load for 5 minutes,
releasing both steering clutches as often as possible. Remove drain plug
and return it to tool box. Drain, and perniit clutches to dry.
(6) Lubricate clutch throwout bearings and mechanism.
(7) Drain, flush and refill final drive compartment with lubricant
recommended on lubrication guide.
(8) Use similar procedure for washing master clutch. Lubricate re-
lease mechanism and linkage by splashing about one quart of OIL,
engine, SAE 10, against back of clutch assembly and over release assem-
bly linkage. Allow oil to drain from clutch compartment.
g. Power Take-Off. CAUTION: Bearings of the upper power take-
off shaft are splash-lubricated. If the tractor is used with the power
take-off disengaged, these bearings will receive no lubrication. Power
take-off should be engaged at least once a day and operated for a few
minutes to assure that these bearings receive lubrication. Breather cap
on top of power take-off housing should be washed periodically in clean
Diesel fuel.
33
TM 9-787A
29
HEAVY TRACTOR MT
Crankcase drain plug
CAUTION-lubricate Dotted
Arrow Points on BOTH SIDES
Lubricant • InUrval
Front idler Iplugl GO Un\
(Note S) ',
Stabilizer link and shaft C6 8
Stabilizer crank support C6 I ,
Track support roller 60 UH.'.n
(plug) (Note 51 ■"'
Track release spring OE (M
housing ISAE SOI .
(Fill plug. Level plug on
early models) (Note 4)
Track release spring
homing level plug
(late models)
Track release spring
bousing drain plug
(late modelsl
Truck wheels (plugs) EO 141
(Lubricate 5 wheels)
(Note 5)
Bell crank pivot pin CG 8 -
(Note
Steering clutch CG 8 -
throwout brgs. (Note 61
Brake bell crank CG128-
(Sparingljr) (Note 6)
Steering c/irfcA comp.
drain plug (Note 7)
Final drive drain plug '
Final drive (See Table) 60 240 '
(Fill and level plug)
(Note 41
SERVICED FItOM UNDER HOOD
Interval • Lubricant
240 C6 Fan (fittingi
t4 OE Generator (Sparingly)
64 OE Air compressor
(Fill and level plug)
(Note 12)
Air compressor drain plug
UOilfilferimen)
240 OE Starter (Sparingly)
(Note 11)
240 Oil mier
(2nd stage) (Note 101
(Not on late modelsl
~^ (M C6 Throttle lever disc (plug)
(Sparingly)
Fuel iSliers (Secondary)
(Note 91
64' OE Crankcase (See Table)
Drain, refill (Note 3)
Check level daily
8 C6 Clutch release bearing
8 OE Air cleaners (Note 2)
IJtiCG Clutch cams (Note 8)
Engine clutch comp*
drain plug (Note 7)
248 CG Air brake valve lever
iN 60 Transmission (See Table)
(Fill plug and level gage)
(Note 41
Transmission drain plug
Fuelfilfers (Primary)
(Note 9)
8 CG Pintle hooks
■ KEY-
LUBRICANTS
OE — OIL, engine
Crankcase grade
GO — LUBRICANT, gear, universal
- GREASE, general purpose
No. 1 (above + 32°)
No. (+32°toO°>
INTERVALS
8 — 8 HOURS
64 — 64 HOURS
128 — 1 28 HOURS
240 — 240 HOURS
6M — 6 MONTHS
CHECK DAILY
Crankcase
Air cleaner
TABLE OF CAPACITIES AND LUBRICANTS TO BE USED
Capacity
Above +32" | +32° to 0°
Below 0°
CRANKCASE
13 qt.
Caution; Use on
OE
SAE 30
ly U.S. Army Spec. 2
OE
SAE 10
-104a
Refer
to
para.
135
TRANSMISSION
24 qt.
GO
SAE 90
GO
SAE 80
FINAL DRIVE (each
uniti 8 qt.
RA PD 53972
figure 17— Lubrication Guide
34
TM 9-787A
29
LUBRICATION
NOTES
Additional Lubrication and Service Instructions on Individual Units and Ports
COLD WEATHER: For Lubrication and Service below 0°, refer to Sect. XXV
1. FITTINGS — Clean before applying lubricant. (Winch) Lubricate until new grease is forced from the
bearing, unless otherwise specified. CAUTION: Lubricate after washing tractor.
2. AIR CLEANERS — Proper maintenance of air cleaners is essential to prolonged engine life. (Engine
air cleaners) Check level every 8 hours. Clean and refill to circular level mork with used cronkcase oil or
OIL. engine, cronkcase grade, every 8 to 30 hours, depending on dust conditions. Remove entire air
cleaner twice o yeor. wash and reoil. Clean air pipes and reassemble. Keep all connections tight. Empty
pre-cleaners every 8 hours or more frequently if required. CAUTION: Do not allow dirt level to rise
above top of gloss. (Air compressor oir cleaner) Remove filter mot and wash every 128 hours. (Air
compressor governor air cleaner) Remove and wash strainer every 240 hours.
3. CRANKCASE — Check oil level doily. Drain only when engine is hot. Drain every 64 hours and refill to
FULL mark on gage. Run engine a few minutes and recheck oil level. CAUTION: Be sure pressure goge
indicates oil is circulating.
4. GEAR CASES — Check level weekly, except track release spring housing, check every 240 hours; add
lubricant if necessary. Checkwith tractor on level ground. Make visual inspection for leakoge weekly.
Report leakage to ordnance maintenance personnel. Drain, flush and refill os indicated at points on
Lubricotion Guide. When draining, drain immediately after operation. Clean and reoil gauze in power
take-off fill pipe cap with OIL, engine, cronkcase grade, every 64 hours. CAUTION: Bearings on the
upper power take-off shaft ore splash lubricated. If the tractor is used with the power take-off dis-
engaged, these bearings will receive no lubrication. Power take-off should be engaged at least once a
day and operated for a few minutes to insure that these bearings receive lubrication.
5. TRACK SUPPORT ROLLERS, IDLERS AND TRUCK WHEELS ~ Remove plugs and flush with LUBRI-
CANT, gear, universal, seasonal grade. CAUTION: Service front idlers with tO strokes each, track
support rollers with 8-1/2 strokes each and truck wheels with 6 strokes each, using AC flushing
lubricotor.
6. STEERING CLUTCH THROWOUT BEARINGS, BELL CRANK PIVOT PIN, BRAKE BELL CRANK —
Use GREASE, general purpose, seasonal grode. (Steering clutch throwout bearings and bell crank pivot
pin) Lubricate every 8 hours. (Brake bell crank) Lubricate sparingly every 128 hours. To reach fit-
tings,- remove driver's seat.
7. ENGINE AND STEERING CLUTCH COMPARTMENTS — Remove plugs doily after using tractor to
drain accumulated oil. Replace plugs. CAUTION: Be sure that plugs are in place when operating in
deep mud or water.
a. Steering clutches and engine clutch — Washing of dutch units about every 240 hours is essential
to efficient operation. Use the following procedure: Lubricate throwout bearings until they are filled.
Install plugs in drain holes of steering clutch compartment. Fill compartment with 5 gal. of diesel
fuel or SOLVENT, dry-cleaning, bringing level to about 4 in. below steering clutch shaft. Start engine
and run tractor back and forth for severol minutes without releasing steering clutches. Stop troctor
and drain eoch compartment. Replace plugs and refill with some amount of clean SOLVENT, dry-
cleaning. Operate tractor with no load for. 5 minutes, releasing both steering clutches as often as
possible. Drain and permit clutches to dry. Lubricate clutch throwout bearings and mechanism. Drain,
flush and refill final drive comportments with LUBRICANT, gear, universal. SAE 90.
8. ENGINE CLUTCH CAMS — Remove cover at top of clutch housing, turn crank to reach 3 fittings.
9. FUEL FILTERS — First Stage) Located under seat. Remove and replace element every 300 to 500
hours depending upon operating condition. Be sure gasket around the filter housing is in good condi-
tion. Drain sediment trap through drain plug at bottom of trap. (Second Stogel Remove and renew
cartridge every 300 to 500 hours depending on operating conditions. Fill filter with oil. Be sure gasket
around the filter housing is in good condition. Open drain plug doily to remove sediment and water.
(Third Stage) Remove ond replace element every 300 to 500 hours depending on operating condition.
Install spring and element with end marked "top" up. Fill filter with fuel. Install new gasket. If cotton
wound filter element is used, place washer over hollow stud in filter housing.
10. OIL FILTER — Clean oil filters at eoch cronkcase oil change. Remove drain plug in filter base and
drain filter body. Remove nut from top of filter' body and lift off center shell. Remove filter elements.
Wash elements in diesel fuel being careful not to scratch or distort elements. Dry oil ports and re-
ossemble filter. After cleaning filter, refill cronkcase to FULL mark on gage. Run engine o few minutes
and recheck oil level. Early models) Every 240 hours or every fourth oil change, wash filter base and
shell and install new cartridge in secondary stage filter.
1 1 . STARTER — Use OIL, engine, SAE 30, sparingly every 240 hours. If removed, lubricate outboard bear-
ing through oiler with OIL, engine, SAE 30.
12. COMPRESSED AIR TANK — Drain water from air tank doily.
13. UNIVERSAL JOINTS AND SLIP JOINT — Remove guard. Lubricate with GREASE, general purpose,
seasonal grade. (Eorly models) Remove plugs and insert fittings to lubricate. Replace plugs. (Late
models) Lubricate through fittings,
14. WINCH JAW CLUTCH — -When operating in dusty or muddy conditions, the sliding jaw clutch must
be cleaned frequently and oiled with OIL. engine, seasonal grade, to insure smooth operation,
15. OIL CAN POINTS — Lubricate control shafts and clevises with OIL, engine, cronkcase grade, every
64 hours.
16. POINTS REQUIRING NO LUBRICATION — Tracks, clutch pilot bearing, chain.
RA PD 53972B
Notes for Figures 17 and 78
35
TM 9-787A
29
HEAVY TRACTOR Ml
Lubriconf • Interval
Interval • Lubricant
Worm gear housing go 6M
(See Table)
(Check level dally when In
continuous operation)
(Note 4)
Worm gear housing
drain plug
Worm gear housing
level plug
Universal joint CG 8
(Note 13)
Slip joint CG £4
(Note 13)
Universal joint cG
• (Note 13)
Drive shaft bearing cG
(CAUTION: Early models, re-
move plug, fill to level only:
use taper tip gun)
(Late models, fitting)
Drive shaft bearing cG
(Remove chain guard)
(CAUTION: Early models, re-
move plug, fill to level only:
use taper tip gun)
(Late models, fitting)
64 CG Drum bearings (Sparingly)
(Rotate drum to expose
fittings)
8 CG End frame bearing
OE Winch jaw clutch
(Note 14)
Power take-off level plug
6M GO Power takeoff (See Table)
(Note 4)
Powell take-off drain plug
KEY
LUBRICANTS
OE — OIL, engine
SAE 30 (obove +32°)
SAE 10 (+32° to 0°)
GO— LUBRICANT, gear, universal
SAE 90
CG — GREASE, general purpose
No. 1 (above +32°l
No. (+32° to 0°)
INTERVALS
8—8 HOURS
64—64 HOURS
6M— 6 MONTHS
TABLE OF CAPACITIES AND LUBRICANTS TO BE USED
Capacity
Above +32°
+32° to 0°
Below 0°
Power take-off
m at.
GO
SAE 90
GO
SAE 90
Refer
to
pora.
135
Worm Drive Housing
4 at.
RA PD 53973
figure 18— Lubrication Guide— Gar Wood Winch
36
TM 9-787A
29-32
LUBRICATION
h. Winch. Gear cases and other points are lubricated at intervals
corresponding with those for the tractor itself. They should be lubri-
cated, as indicated on the lubrication guide.
i. Winch Jaw Clutch. When operating under dusty or muddy condi-
tions, the sliding jaw clutch must be cleaned frequently and lubricated
with OIL, engine, seasonal grade, to insure smooth operation.
j. Drive Chain. Clean frequently and oil with LUBRICANT, gear,
universal, SAE 90.
k. Clutch Hub and Pilot Bearing. At 100 hour inspection or when
engine is removed, disassemble, clean and repack with GREASE, ball
and roller bearing, and reassemble.
30. POINTS TO BE LUBRICATED BY ORDNANCE MAINTE-
NANCE PERSONNEL.
a. Water Pump. Packed at assembly. If disassembled, clean and
repack bearings with GREASE, ball and roller bearing.
b. Starter. Clean and repack all ball bearings with GREASE,
special, high temperature.
c. Generator.
(1) Clean and repack ball bearings with GREASE, special, high
temperature.
(2) Coat pole and exposed armature shaft surfaces with OIL, engine,
SAE 30, to prevent rusting.
31. REPORTS AND RECORDS.
a. Reports. If lubrication instructions are closely followed, proper
lubricants used, and satisfactory results are not obtained, a report will
be made to the ordnance officer responsible for the maintenance of the
materiel.
b. Records. A complete record of lubrication servicing will be kept
for the materiel.
32. SUPPLEMENTARY LUBRICATION ILLUSTRATIONS.
a. The location of lubrication fittings and methods of lubrication are
shown in figures 17 to 23 inclusive.
37
TM 9-787A
32
HEAVY TRACTOR Ml
STARTING MOTOR
Figure 19— Lubrication Fittings
38
TM 9.787A
32
LUBRICATION
RA PD 17221
figure 20— Lubrication Fittings
39
TM 9-787A
32
HEAVY TRACTOR Ml
TRUCK WHEELS
figure 21 —Lubrication Fittings
40
RA PD 17220
LUBRICATION
TM 9-787A
32
RA PD 17226
Figure 27— Cutaway Truck Wheel with Flushing Lubricator,
Figure 23— Lubricating Truck Wheels
41
RA PD 17265
TM 9-787A
33-34
HEAVY TRACTOR Ml
Section V
PREVENTIVE MAINTENANCE
Paragraph
General 33
Prestarting inspection 34
Inspection during operation 35
Inspection after operation 36
Inspection after each 50 hours of operation 37
Inspection after each 100 hours of operation 38
Inspection for operation in water 39
Inspection for operation in deep snow 40
Inspection for operation in sandy terrain 41
Insp)ection for operation in deep mud 42
33. GENERAL.
a. To insure mechanical efficiency, it is necessary that the tractor
be systematically inspected at regular intervals in order that defects
may be discovered and corrected, and the necessary adjustments made
before damage results.
b. Cracks that develop in castings or other metal parts may often
be detected by dust and oil deposits after the completion of a run.
General wear of all parts should be noted at all inspection periods, and
parts needing replacement because they are nearly worn out, should be
reported before break-down occurs.
34. PRESTARTING INSPECTION.
a. Before the engine is started, the operator or organization per-
sonnel should check the following:
(1) Check the fuel supply.
(2) Remove the bayonet gage to determine engine crankcase oil
level. If found to be below "FULL" mark, add one quart of the correct
oil for each mark that level is below "FULL."
(3) Check air compressor oil level. Add oil if necessary.
(4) Inspect water or antifreeze solution in cooling system. Add liquid
if no water can be seen when radiator cap is removed.
(5) Inspect the entire unit for loose bolts or nuts if repairs have
been made since the previous operating period.
(6) Check oil level in final drives. Keep filled to level of filler plug.
(7) Check transmission oil level. This level should be kept between
"LOW" and "FULL" marks on bayonet gage.
42
TM 9-787A
34-36
PREVENTIVE MAINTENANCE
(8) Make inspection of tractor tool equipment. Report any tools or
special equipment missing.
(9) Inspect for presence of fire extinguisher.
(10) Make sure that all operating levers work freely and correctly.
(11) Make sure that all lights and brakes are in operating condition.
(12) Make sure that equipment which tractor is pulling is securely
hitched and safety cables or chains are in place.
(13) Observe operating instruments. Oil pressure gage should read
zero, fuel pressure gage zero, ammeter zero, etc.
(14) Drain fuel tank sediment sumps.
(15) Drain second stage fuel filters.
35. INSPECTION DURING OPERATION.
a. An operator should make it a habit to glance often at the operating
instruments to be sure all parts of tractor are functioning properly. He
should be alert for indications of abnormal operation of the engine and
tractor. If instruments fluctuate abnormally, the cause should be im-
mediately determined. After engine reaches operating temperature (170
F to 180 F), oil pressure should be 25 to 35 pounds, fuel pressure 20 to
30 p>ounds at three quarters or full throttle. Radiator shutter should be
regulated to keep engine at operating temperature.
b. Operator should note if master clutch engages and disengages prop-
erly and if pull required to engage clutch is 50 to 55 pounds when engine
is running.
c. The steering levers and brake pedals should be checked for clear-
ances and operation.
d. Any slippage of clutches should be detected and corrective
measures taken immediately.
36. INSPECTION AFTER OPERATION.
a. The following points should be inspected after operation and all
oil levels brought up to "FULL."
( 1 ) Engine and air compressor crankcases oil level.
(2) Transmission case oil level.
(3) Final drive gear cases oil level.
(4) Winch gear housing oil level.
(5) Power take-off oil level.
(6) Cooling system. Add water if necessary.
(7) Batteries. Keep water level three eighths of an inch above sep-
arators.
43
TM 9-787A
36
HEAVY TRACTOR Ml
(8) Precleaners. Empty dirt out of compartments.
(9) Air cleaners. Remove oil cups, clean and refill to proper level.
(10) Open fuel tank drain cocks to remove water and dirt from
sediment sumps.
(11) Open air tank cocks to allow any accumulated water to drain
out.
(12) Inspect for loose bolts, nuts, or broken parts.
AIR COMPRESSOR AIR FILTER
THERMOSTAT PLUG
WATER DRAIN
WATER DRAIN
THIRD STAGE
FUEL FILTER
SECOND STAGE
FUEL FILTER
AIR TANK WATER DRAIN
Figure 24— Service Chart
44
RA PD 17244
TM 9-787A
37-39
PREVENTIVE MAINTENANCE
37. INSPECTION AFTER EACH 50 HOURS OF OPERATION.
a. Check.
(1) Master clutch adjustment (par. 108).
(2) Steering clutch throwout adjustment (par. 112).
(3) Brake adjustment (par. 115).
(4) Front idler and track adjustment (par. 120).
(5) Winch worm shaft safety brake (par. 125).
38. INSPECTION AFTER EACH 100 HOURS OF OPERATION.
a. Check.
(1) Generator belt adjustment (par. 87).
(2) Air compressor belt adjustment (par. 103).
(3) Fan belt adjustment (par. 80).
(4) Remove air compressor filter mat and wash in gasoline. Do this
more often in extremely dusty conditions (par. 103).
- (5) Wire insulation and connections.
(6) Check fuel filters under seat. Install new filter elements if
necessary,
b. See that air box vent tube is not clogged. Remove and clean if
necessary.
c. Measure engine valve clearance. Adjust to 0.010 inch, with engine
at operating temperature (par. 60).
39. INSPECTION FOR OPERATION IN WATER.
a. Before driving the tractor into water, the operator should estimate
what the maximum depth will be, the kind of footing the tractor will
have for traction, and the length of time the tractor will be in the water.
b. If the water is over 20 inches deep, the two large pipe plugs in the
tractor tool box should be installed in the two drain holes in the bottom
of the transmission case. This will prevent water getting into the steering
clutch compartment. The small pipe plug should be installed in the
drain hole of the master clutch compartment.
c. With these plugs installed, the tractor is capable of operating in
water up to a depth of about 41 inches. The ends of the fan blades,
when at the lowest point, are 41% inches above the ground (measured
from the tip of the grousers). As long as the fan blades do not hit the
water, no damage will result. If the fan blades do hit the water, the
angle of the blades is such that they will bend out and cut into the
radiator core.
d. After operating in water, the drain plugs should be removed.
The, tractor should be allowed to stand for a short while and the drain
plugs in the final drive cases and track release housings loosened and
removed partially to see if any water or dirt has entered these housings.
45
TM
9-787A
39
HEAVY TRACTOR Ml
AIR PRE-CLEANERS ;
LSECON'D STAGE FU EL FILTER
SERVICE
Tractor, Heavy, Ml
Air Pre-Cleaners — Remove and
clean dirt compartment after
operation or more often in ex-
tremely dusty condition. Level of
dirt in compartment should never
be allowed to become higher
than top of glass.
Fuel Filters — Replace fuel filter
'elements in first stage fuel filter,
second stage fuel filter and third
stage fuel filter monthly or
whenever a drop in fuel pressure
indicates fuel filters are clogged.
Batteries — Check water level in
batteries, located under seat,
after operation and add distilled
water regularly to keep water
level %" above separators. Keep
top of batteries and terminals
clean. "»* p" '"-»'
Figure 25— Service Instructions
46
TM 9-787A
39
PREVENTIVE MAINTENANCE
SERVICE
Tractor, Heavy, Ml
Coaling System — Both woter pump
drain and rodiator drain should
be opened to completely drain
system. When filling system
thermostat plug must be re-
moved, until water reaches level
of plug, to allow air to escape.
Drain, flush, ond refill cooling
system monthly.
Air Compressor Filter — Remove oir
compessor fifter and wash out
with gasoline or fuel oil every
100 hours or oftener in dusty
conditions. Saturate filter mat
with light engine oil before
replacing.
Air Reservoir — Open drain cock on
bottom of tank after operation
to oilow any accumulated water
to drain out.
Sediment Sumps — Drain woter and
dirt from sediment sumps,
located under fuel tank, after
operation. This should be done
before ecctf operating period.
RA PD 18045
Figure 26— Service Instructions
47
TM 9-787A
39-42
HEAVY TRACTOR Ml
This is especially important in cold weather when the water might
freeze. If any water or dirt has entered these compartments, they
should be drained, flushed out, and refilled with clean oil.
e. The plugs used in the master clutch and steering clutch compart-
ments should always be put in tractor tool box when removed to prevent
loss and insure having them with tractor when again needed.
40. INSPECTION FOR OPERATION IN DEEP SNOW.
a. Before driving in deep snow, install the two large pipe plugs in
the drain holes in the bottom of the transmission case to prevent snow
getting into the steering clutch compartment. The small pipe plug
should be installed in the drain hole of the master clutch compartment.
b. After the vehicle has been operated in deep snow, the following
inspection should be made:
( 1 ) Remove snow which has become hard-packed in the track open-
ings, and inspect track rollers and truck wheels for any damage.
(2) Inspect bottom of vehicle for any damage which may have been
caused by striking objects hidden in the snow.
(3) Inspect final drive cases and track release housing for water
and dirt. Drain, flush out, and refill with clean oil if necessary.
41. INSPECTION FOR OPERATION IN SANDY TERRAIN.
a. Before driving in sand, install pipe plugs in the drain holes in the
transmission case and the master clutch compartment.
b. After the vehicle has been operated in sandy terrain and dust
laden atmosphere, the following inspection should be made:
(1) Inspect precleaner and remove any accumulated dirt.
(2) Inspect air cleaner, and clean and refill with new oil if necessary.
(3) Inspect fuel and oil filters. Clean filters or replace filtering ele-
ment where required.
42. INSPECTION FOR OPERATION IN DEEP MUD.
a. Before driving in deep mud, install the pipe plugs in the drain
holes in the transmission case and the master clutch compartment.
b. After the vehicle has been operated in deep mud, it should be
thoroughly washed, all mud removed, and the following inspections
made :
( 1 ) Inspect lubrication fittings to determine if they have become
clogged with mud. Remove any mud present, and lubricate part.
(2) Check rollers and truck wheels for free movement to determine
if any mud has found its way into the bearings.
(3) Inspect final drive cases and track release housing for water and
mud. Drain, flush out, and refill with clean oil if necessary.
48
TM 9-787A
43-44
Section VI
GENERAL CARE AND PRESERVATION
Paragraph
Records 43
Cleaning 44
43. RECORDS.
a. Use. An accurate record must be kept of each motor vehicle
issued by the Ordnance Department. For this purpose the Ordnance
Motor Book (O. O. Form No. 7255), generally called "Log Book," is
issued with each vehicle and must accompany it at all times. This
book furnishes a complete record of the vehicle from which valuable
- information concerning operation and maintenance costs, etc., is ob-
tained, and organization commanders must insist that correct entries
be made. This book will habitually be kept in a canvas cover to pre-
vent it from being injured or soiled.
b. Aggignment Record. The page bearing a record of assignment
must be destroyed prior to entering a combat zone. All other references
which may be posted regarding the identity of the organization must
also be deleted.
44. CLEANING.
a. Grit, dirt, and mud are the sources of greatest wear to a vehicle.
If deposits of dirt and grit are allowed to accumulate, particles will
soon find their way into bearing surfaces, causing unnecessary wear,
and, if the condition is not remedied, will soon cause serious difficulty.
When removing engine parts or any other unit, in making repairs and
replacements, or, if in the course of inspection, working joints or bearing
surfaces are to be exposed, all dirt and grit that might find its way to the
exposed surfaces must first be carefully removed. The tools must be
clean, and care must always be taken to eliminate the possibilities of
brushing dirt or grit into the opening with the sleeve or other part of
the clothing. To cut oil-soaked dirt and grit, hardened grit, or road oil,
use SOLVENT, dry-cleaning, applied with cloths (not waste) or a brush.
Care should be taken to keep water from entering electrical accessories
such as starter, generator, etc. Detailed information on cleaning is
included in TM 9-850.
b. Oil cups or grease fittings which have become clogged should
be opened with a piece of wire. Wood should never be used for this
purpose, as splinters are likely to break off and permanently clog these
passages. Particular care should be taken to clean and decontaminate
vehicles that have been caught in a gas attack. See section VIII for
details of this operation.
49
TM 9-787A
45-46
HEAVY TRACTOR Ml
Section VII
PAINTING
Paragraph
General 45
Preparing for painting 46
Painting metal surfaces 47
Paint as a camouflage 48
Removing paint 49
Painting lubricating devices 50
45. GENERAL.
a. Ordnance materiel is painted before issue to the using arms and
one maintenance coat per year will ordinarily be ample for protection.
With but few exceptions this materiel will be painted with ENAMEL,
synthetic, olive-drab, lusterless. The enamel may be applied over old
coats of long oil enamel and oil paint previously issued by the Ordnance
Department if the old coat is in satisfactory condition for repainting.
b. Paints and enamels are usually issued ready for use and are ap-
plied by brush or spray. They may be brushed on satisfactorily when
used unthinned in the original package consistency or when thinned
no more than 5 percent by volume with THINNER. The enamel will
spray satisfactorily when thinned with 15 percent by volume of
THINNER. (Linseed oil must not be used as a thinner since it will
impart a luster not desired in this enamel.) If sprayed, it dries hard
enough for repainting within Va hour and dries hard in 16 hours.
c. Complete information on painting is. contained in TM 9-850.
46. PREPARING FOR PAINTING.
a. If the base coat on the materiel is in poor condition, it is more
desirable to strip the old paint from the surface than to use sanding
and touch-up methods. After stripping, it will then be necessary to
apply a primer coat.
b. PRIMER, ground, synthetic, should be used on wood as a base
coat for synthetic enamel. It may be applied either by brushing or
spraying. It will brush satisfactorily as received or after the addition
of not more than 5 percent by volume of THINNER. It will be dry
enough to touch in 30 minutes, and hard in 5 to 7 hours. For spraying,
it may be thinned with not more than 15 percent by volume of THIN-
NER. Lacquers must not be applied to the PRIMER, ground, synthetic,
within less than 48 hours.
50
TM 9-787A
46-48
PAINTING
c. PRIMER, synthetic, rust-inhibiting, for bare metal, should be
used on metal as a base coat. Its use and application is similar to that
outlined in subparagraph b above.
d. The success of a job of painting depends partly on the selection
of a suitable paint, but also largely upon the care used in preparing the
surface prior to painting. AU parts to be painted should be free from
rust, dirt, grease, kerosene, oil, and alkali, and must be dry.
47. PAINTING METAL SURFACES.
a. If metal parts are in need of cleaning, they should be washed
in a liquid solution consisting of Vi pound of SODA ASH in 8 quarts
of warm water, or an equivalent solution, then rinsed in clear water and
wiped thoroughly dry. Wood parts in need of cleaning should be treated
in the same manner, but the alkaline solution must not be left on for
more than a few minutes and the surfaces should be wiped dry as soon
as they are washed clean. When artillery or automotive equipment is in
fair condition and only marred in spots, the bad places should be touched
with ENAMEL, synthetic, olive-drab, lusterless, and permitted to dry.
The whole surface will then be sandpapered with PAPER, flint. No. 1,
and a finish coat of ENAMEL, synthetic, olive-drab, lusterless, applied
and allowed to dry thoroughly before the materiel is used. If the equip-
ment is in bad condition, all parts should be thoroughly sanded with
PAPER, flint. No. 2, or equivalent, given a coat of PRIMER, ground,
synthetic, and permitted to dry for at least 16 hours. They will then be
sandpapered with PAPER, flint, No. 00, wiped free from dust and dirt,
and a final coat of ENAMEL, synthetic, olive-drab, lusterless, applied
and allowed to dry thoroughly before the materiel is used.
48. PAINT AS A CAMOUFLAGE.
a. Camouflage is now a major consideration in painting ordnance
vehicles, with rust prevention secondary. The camouflage plan at present
employed utilizes three factors: color, gloss, and stenciling.
(1) Color. Vehicles are painted with ENAMEL, synthetic, olive-
drab, lusterless, which was chosen to blend in reasonably well with the
average landscape.
(2) Gloss. The lusterless enamel makes a vehicle difficult to see
from the air or from relatively great distances over land. A vehicle
painted with ordinary glossy paint can be detected more easily and at
greater distances.
(3) Stenciling. White stencil numbers on vehicles have been elimi-
nated because they can be photographed from the air. A blue-drab
stencil enamel is now used which cannot be so photographed. It is
illegible to the eye at distances exceeding 75 feet.
51
TM 9-787A
43-50
HEAVY TRACTOR Ml
b. Preserving Camouflage.
( 1 ) Continued friction or rubbing must be avoided, as it will smooth
the surface and produce a gloss. The vehicle should not be washed more
than once a week. Care should be taken to see that the washing is done
entirely with a sponge or a soft rag. The surface should never be rubbed
or wiped, except while wet, or a gloss will develop.
(2) It is not desirable that vehicles, painted with lusterless enamel,
be kept as clean as vehicles were kept when glossy paint was used. A
small amount of dust increases the camouflage value. Grease spots should
be removed with SOLVENT, dry-cleaning. Whatever portion of the spot
cannot be so removed should be allowed to remain.
(3) Continued friction of wax-treated tarpaulins on the sides of a
vehicle will also produce a gloss, which should be removed with SOL-
VENT, dry-cleaning.
(4) Tests indicate that repainting with olive-drab paint will be
necessary once yearly, with blue-drab paint twice yearly.
49. REMOVING PAINT.
a. After repeated paintings, the paint may become so thick as to
crack and scale off in places, presenting an unsightly appearance. If
such is the case, remove the old paint by use of a lime-and-lye solution
(see TM, 9-850 for details) or REMOVER, paint and varnish. It is
important that every trace of lye or other paint remover be completely
rinsed off and that the equipment be perfectly dry before repainting is
attempted. It is preferable that the use of lye solutions be limited to
iron or steel parts. If used on wood, the lye solution must not be al-
lowed to remain on the surface for more than a minute before being
thoroughly rinsed off and the surface wiped dry with rags. Crevices or
cracks in wood should be filled with putty and the wood sandpapered
before refinishing. The surfaces thus prepared should be painted accord-
ing to directions in paragraph 47.
50. PAINTING LUBRICATING DEVICES.
a. Oil cups, grease fittings, oilholes, and similar lubricating devices,
as well as a circle about three-fourths of an inch in diameter at each
point of lubrication, will be painted with ENAMEL, red, water-resist-
ing, in order that they may be readily located.
52
TM 9-787A
51-53
Section VIII
MATERIEL AFFECTED BY GAS
Paragraph
Protective measures 51
Cleaning 52
Decontamination 53
Special precautions for automotive materiel 54
51. PROTECTIVE MEASURES.
a. When materiel is in constant danger of gas attack, unpainted metal
parts will be lightly coated with engine oil. Instruments are included
among the items to be protected by oil from chemical clouds or chemical
shells. Care will be taken that the oil does not touch the optical parts
of instruments or leather or canvas fittings. Materiel not in use will
be protected with covers as far as possible.
b. Ordinary fabrics offer practically no protection against mustard
gas or lewisite. Rubber and oilcloth, for example, will be penetrated
within a short time. The longer the period during which they are ex-
posed, the greater the danger of wearing these articles. Rubber boots
worn in an area contaminated with mustard gas may offer a grave
danger to men who wear them several days after the bombardment. Im-
permeable clothing will resist penetration more than an hour, but should
not be worn longer than this.
52. CLEANING.
a. All unpainted metal parts of materiel that have been exposed
to any gas except mustard and lewisite must be cleaned as soon as pos-
sible with SOLVENT, dry-cleaning, or ALCOHOL, denatured, and
wiped dry. All parts should then be coated with engine oil.
53. DECONTAMINATION.
a. For the removal of liquid chemicals (mustard, lewisite, etc.) from
materiel, the following steps should be taken:
( 1 ) Protective Measures.
(a) For all of these operations a complete suit of impermeable cloth-
ing and a service gas mask will be worn. Immediately after removal of
the suit, a thorough bath with soap and water (preferably hot) must be
taken. If any skin areas have come in contact with mustard, if even a
very small drop of mustard gets into the eye, or if the vapor of mustard
has been inhaled, it is imperative that complete first-aid measures be
given within 20 to 30 minutes after exposure. First-aid instructions are
given in TM 9-850 and FM 2 1-40.
53
TM 9-787A
53
HEAVY TRACTOR Ml
(b) Garments exposed to mustard will be decontaminated. If the
impermeable clothing has been exposed to vapor only, it may be de-
contaminated by hanging in the open air, preferably in sunlight for
several days. It may also be cleaned by steaming for 2 hours. If the
impermeable clothing has been contaminated with liquid mustard, steam-
ing for 6 to 8 hours will be required. Various kinds of steaming devices
can be improvised frorn materials available in the field.
(2) Procedure.
(a) Commence by freeing materiel of dirt through the use of sticks,
rags, etc., which must be burned or buried immediately after this opera-
tion.
(b) If the surface of the materiel is coated with grease or heavy oil,
this grease or oil should be removed before decontamination is begun.
SOLVENT, dry-cleaning, or other available solvents for oil should be
used with rags attached to ends of sticks.
(c) Decontaminate the painted surfaces of the materiel with bleach-
ing solution made by mixing one part AGENT, decontaminating (chlo-
ride of lime), with one part water. This solution should be swabbed
over all surfaces. Wash off thoroughly with water, then dry and oil all
surfaces.
(d) All unpainted metal parts and instruments exposed to mustard
or lewisite must be decontaminated with AGENT, decontaminating,
noncorrosive, mixed one part solid to fifteen parts solvent (ACETY-
LENE TETRACHLORIDE). If this is not available, use warm water
and soap. Bleaching solution must not be used, because of its corrosive
action. Coat all metal surfaces lightly with engine oil.
(e) In the event AGENT, decontaminating (chloride of lime) is not
available, materiel may be temporarily cleaned with large volumes of
hot water. However, mustard lying in joints or in leather or canvas
webbing is not removed by this procedure and will remain a constant
source of danger until the materiel can be properly decontaminated.
All mustard washed from materiel in this manner lies unchanged on the
ground, necessitating that the contaminated area be plainly marked
with warning signs before abandonment.
({) The. cleaning or decontaminating of materiel contaminated with
lewisite will wash arsenic compounds into the soil, poisoning many water
supplies in the locality for either men or animals.
(g) Leather or canvas webbing that has been contaminated should
be scrubbed thoroughly with bleaching solution. In the event this treat-
ment is insufficient, it may be necessary to burn or bury such materiel.
(h) ■ Detailed information on decontamination is contained in FM
21-40, TM 9-850, and TO 38, 1941, Decontamination.
54
TM 9-787A
54
MATERIEL AFFECTED BY GAS
54. SPECIAL PRECAUTIONS FOR AUTOMOTIVE MATERIEL.
a. When vehicles have been subjected to gas attack with the engine
running, the air cleaner should be serviced by removing the oil, flushing
with SOLVENT, dry-cleaning, and refilling with the proper grade of oil.
b. Instrument panels should be cleaned in the same manner as out-
lined for instruments.
c. Contaminated seat cushions will be discarded.
d. Washing the compartments thoroughly with bleaching solution is
the most that can be done in the field. Operators should constantly be
on the alert, when running under conditions of high temperatures, for
slow vaporization of the mustard or lewisite.
e. Exterior surfaces of vehicles will be decontaminated with bleach-
ing solution. Repainting may be necessary after this operation.
55
TM 9-787A
55
HEAVY TRACTOR Ml
PART TWO — Organization instructions
Section IX
GENERAL INFORMATION ON MAINTENANCE
Paragraph
Scope 55
55. SCOPE.
a. The scope of maintenance and repairs by the crew and other units
of the using arms is determined by the ease with which the project can
be accomphshed, the amount of time available, weather conditions,
temperatures, the equipment available, the skill of the personnel, and
other circumstances which may be present.
b. The definitions given below are included in order that the opera-
tion prescribed may be correctly interpreted by those doing the work.
( 1 ) Service. Consists of cleaning, lubricating, tightening bolts and
nuts, and making external adjustments of subassemblies or assemblies
and controls.
(2) Repair. Consists of making repairs to, or replacements of, a
part, subassembly or assembly that can be accomplished without com-
pletely disassembling the subassembly or assembly, and does not re-
quire heavy welding or riveting, machining, fitting, and/or alining.
(3) Replace. Consists of removing the part, subassembly or assembly
from the tractor and replacing it with a new, reconditioned; or rebuilt
part, whichever the case may be.
(4) Rebuild. Consists of completely reconditioning and placing in
serviceable condition any unserviceable part, subassembly or assembly
of the tractor including welding, riveting, machining, fitting, alining,
assembling, and testing.
c. The following are the maintenance duties which may be per-
formed by the using arm personnel. NOTE: The using arm personnel
is authorized to remove and reinstall an engine or transmission assembly.
However, the replacement of an engine with another engine, or the
replacement of a transmission assembly with another transmission
assembly, must not be done by using arms unless authorization is re-
ceived tram ordnance personnel.
56
TM 9-787A
55
GENERAL INFORMATION ON MAINTENANCE
ENGINE
Engine (par. 55 c, Note) Replace
Engine (pars. 63 and 64) Clean and service
Valve rocker assembly (par. 59) Replace
Valve clearance (par. 60) Adjust
Exhaust manifold and muffler (par. 62) Replace
FUEL AND AIR SYSTEM
Fuel tank (par. 66) Clean and replace
Fuel filters (par. 68) Service or replace
Fuel pump (par. 69) . . . .^. Replace
Injectors (par. 70) . Adjust or replace
Fuel lines and connections (par. 71) Repair or replace
Precleaners (par. 72) Service or replace
Air cleaner (par. 73) Service or replace
COOLING SYSTEM
Water pump assembly (par. 75) Replace
Manifold (par. 76) Replace
Radiator (par. 77) Clean and flush
Thermostat assembly (par. 78) Replace
Hoses and pipes (par. 79) Replace
Fan assembly (par. 80) Replace
Fan belt (par. 80) Service or replace
LUBRICATING SYSTEM
Oil lines Replace
Oil filter (par. 83) Replace
Oil cooler (par. 84) Replace
ELECTRICAL SYSTEM
Batteries (par. 86) Service or replace
Generator (par. 87) Replace
Generator voltage control unit (par. 88) Replace
Starting motor assembly (par. 89) Replace
Ammeter (par. 90) Replace
Hour meter (par. 91) Replace
Air heater (par. 92) Replace
All switches (par. 93) Replace
All lamps (par. 94) Aline, service, or replace
All wires (par. 96) Repair or replace
57
TM 9-787A
55
HEAVY TRACTOR Ml
NONELECTRICAL INSTRUMENTS
Oil pressure gage (par. 97) Replace
Fuel pressure gage (par. 98) Replace
Temperature gage (par. 99) Replace
Air pressure gage (par. 100) Replace
Mile meter (par. 101) Replace
ELECTRIC AND AIR BRAKE SYSTEM
Air compressor assembly (par. 103) Service or replace
Air brake controls (par. 103) Replace
Electric brake controls (par. 104) Replace
MASTER CLUTCH
Master clutch assembly (par. 108) Adjust or wash
STEERING CLUTCHES
Steering clutches (pars. 112 and 113) Adjust or wash
TRACTOR BRAKES
Steering brakes (par. 115) Adjust
FINAL DRIVE ASSEMBLY
Sprocket hub bearings (par. 118) Adjust
TRACKS AND TRUCK FRAME ASSEMBLY
Front idlers (par. 120) Service or replace
Track release assembly (par. 120) Adjust
Truck wheels (par. 121) Service or replace
Truck wheel guards (par. 121) Replace
Track support rollers (par. 122) Service or replace
Track shoe or plate Replace
Pintle drawbar (par. 123) Replace
Pintle bracket (par. 123) Replace
WINCH
Winch assembly (par. 125) Adjust
Winch cables (par. 125) Replace
MISCELLANEOUS
Lubrication (pars. 27 to 32)
Tractor cleaning (par. 44)
Tractor painting (pars. 45 to 50)
d. In the following sections on maintenance of the tractor, specific
mention is not always made of lock washers, cotter keys, and safety
wire. It is to be understood that whenever these items are removed they
are to be reinstalled or replaced at assembly.
58
TM 9-787A
56
Section X
STANDARD TOOLS AND EQUIPMENT
Paragraph
Equipment and location 56
Care of equipment 57
56. EQUIPMENT AND LOCATION.
a. The items listed below are furnished as standard equipment with
each tractor and are in tool boxes on the tractor.
Equipment Stowage Petition
BLOCK, snatch (1) . . Inbox
BOOK, model HD-10 instruction, (1) In box
BOOK, model HD-'IO parts, ( 1 ) In box
CHAIN, tow (1) Inbox
CLIP, for attachmg seat back cushions (2) Inbox
FULCRUM, valve lifter (used with valve lifter and
injector remover tool) (1) In tool box
GASKET, plug (2) Inbox
GUN, hand grease, push type ( 1 ) In box
GUN, pressure grease, with hose, lever type ( 1 ) In box
HAMMER (1) In tool box
KIT, injector service (1) includes: In tool box
BRUSH, large (1) GAGE, timing (1)
BRUSH, small (1) STONE (1)
DRILL (1) VISE, pin (1)
GAGE, feeler ( 1 ) WIRE, probing ( 1 )
KIT, wrench (1) includes: In tool box
WRENCH, open-end, 'Aa-in. WRENCH, open-end, Vs-in.
—1/2 -in. (1) —3/4 -in. (1)
WRENCH, open-end, % „-in. WRENCH, open-end, Vg-in.
— "/fi-in. (1) — li/i«-in. (1)
WRENCH, open-end, 1%2-in. WRENCH, open-end, 1-in.
— 2%0-in. (1) — iy4-in. (1)
LUBRICATOR, flushing, with hose ( 1 ) In box
PLIERS (1) In tool box
PLUG, pipe Va-in. std. (1) Inbox
PREHEATER, engine (1) Inbox
SCREW, cap, for attaching seat back cushions (4) Inbox
SCREWDRIVER (1) In tool box
TOOL, valve lifter and injector removal ( 1 ) In tool box
WASHER, lock %-in. for attaching seat back cushions (4) . . . . . Inbox
59
TM 9-787A
56
HEAVY TRACTOR Ml
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60
TM 9-787A
56-57
STANDARD TOOLS AND EQUIPMENT
Equipment Stowage Position
WRENCH, engine cranking (1) In tool box
WRENCH, fan adjusting (1) In tool box
WRENCH, fuel pump (1) In tool box
WRENCH, hexagon, Vz-in. (1) In tool box
WRENCH, hexagon plug (1) In tool box
WRENCH, injector nut ( 1 ) In tool box
WRENCH, square plug (1) In tool box
WRENCH, track bolt socket (1) In tool box
WRENCH, track release adjusting (1) In tool box
WRENCH, water drain (1) In tool box
List of approved lubricating oils for use in positive seal
assemblies, transmission, and final drives In box
57. CARE OF EQUIPMENT.
a. An accurate record of all tools and equipment should be kept in
order that their location and condition may be known at all times. Items
becoming lost or unserviceable should be immediately replaced. All
tools and equipment should be cleaned and in proper condition for
further use before being returned to their location.
61
TM 9-787A
58
HEAVY TRACTOR Ml
Section XI
ENGINE
Paragraph
General description and data 58
Rocker arm assembly 59
Valve clearance 60
Governor 61
Exhaust manifold and muffler 62
Removal of engine from tractor 63
Installation of engine in tractor 64
58. GENERAL DESCRIPTION AND DATA (figs. 28 to 32).
a. The engine in this tractor is a water-cooled, 2-cycle Diesel with
two cylinders in line. This engine differs from the conventional 4-cycle
VALVE ROCKER ARM
EXHAUST
BALANCE
SHAFT
AIR INLET
FROM AIR
CLEANER
PISTON
BLOWER ROTOR -
LEFT HELJX
RA PD 56398
Figure 28— Cross Section of Engine Showing Circulation of Air
62
ENGINE
TM 9-787A
58
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63
TM 9.787A
58
HEAVY TRACTOR Ml
LIFTING
RACKET
AIR
COMPRES: OR
GENERAIO
RA PD 17SS6
Figure 30— Engine— Left Side
engine in that it requires only two strokes of the piston, one up and one
down, to complete an operating cycle instead of four strokes as in the
4-cycle engine. In the 2-cycle engine, intake and exhaust occur together
when the piston is at the bottom of its stroke; every upstroke is a com-
pression stroke; every downstroke delivers power. Thus the intake and
exhaust strokes of the 4-cycle engine are eliminated. The 2-cycle
engine exhausts burned gases and fills its cylinders with fresh air, not
by the pumping action of the engine itself, but by means of a rotary
blower mounted on the right side of the engine and driven from the
engine crankshaft. As the piston nears the end of its power stroke,
the exhaust valves (two for each cylinder) in the cylinder head open
to allow the burned gases to escape and the piston uncovers the intake
ports in the lower part of the cylinder wall (64 holes in each cylinder
liner) to permit fresh air from the blower to rush in, forcing burned
gases out through the exhaust valves and filling the cylinder with a
new charge of fresh air (fig. 28). As the piston rises on the compression
stroke, it closes off the intake ports, the exhaust valves close, and the
charge of air is compressed into one-sixteenth of its former volume.
This compression causes the air to become extremely hot. A charge of
64
TM 9-787A
58
ENGINE
f
THERMOSTAT
ASSEMBLY
AIR COMPRESSOR
PULLEY -
GENERATOR
PULLEY
CRANKSHAFT
DRIVE PULLEY
RA PD 17560
Figure 31— Engine— Front View
Diesel fuel is injected into this hot compressed air by the injector, just
before the piston reaches the top of its stroke. The fuel is ignited by
the hot air and burns, and the expansion caused by the combustion of
the gases formed forces the piston down on its power stroke.
b. Basic engine parts are readily accessible. On the right-hand side,
as viewed from the operator's seat, are located the blower, engine
governor, fuel pump, second and third stage fuel filters, lubricating oil
filter and cooler, and water pump. The air compressor, starter, air heater,
and generator are mounted on the left-hand side.
65
TM 9-787A
58
HEAVY TRACTOR Ml
MASTER CLUTCH
ADJUSTMENT LOCK
MASTER CLUTCH
RA PD 17558
Figure 32 —Engine— Rear View
c. The fuel pump and water pump are driven by the lower blower
rotor shaft. The fan and air compressor are driven by V-belts from a
pulley on the crankshaft, and the generator is driven by a V-belt from
the air compressor pulley.
d. The flywheel housing and timing gear cover are bolted directly
to the rear end of the cylinder block. Lifter brackets are provided, at-
tached to the top of the cylinder head. These are used in the removal
or installation of the engine.
66
TM 9-787A
58
ENGINE
e. Tabulated Data.
Make of engine General Motors 4-71 RC14
Weight with accessories, dry (approx.) 1,865 lb
At 2,000 rpm maximum horsepower (engine alone) 110.0
At 1,750 rpm 105.0
Number of cylinders 4
Bore and stroke 4 Vi x 5 in.
Piston displacement 284 cu. in.
Compression ratio 16 to 1
Number of exhaust valves per cylinder 2
Firing order, clockwise rotation (cranking) 1-3-4-2
Crankcase capacity 13 qt
Direction of rotation (viewed from operator's seat) :
Crankshaft Counterclockwise
Starter Clockwise
Generator Counterclockwise
Fuel pump r Clockwise
Water pump Clockwise
Oil pump Counterclockwise
Blower Counterclockwise
Air compressor ^ Counterclockwise
Ratio of accessory drive to crankshaft speed:
Starter 9.27
Generator ■ 1.7
Fuel pump 1.94
Water pump 1.94
Oil pump 1.39
Blower 1.94
Air compressor 0.933
f. Trouble Shooting.
(1) Uneven Running, Excessive Vibration of Engine.
Probable Cause Probable Remedy
Insufficient fuel supply. Check fuel supply and filters
(pars. 66 and 68).
Injectors out of time. Time injectors (par. 70).
Injectors not equalized. Equalize injectors (par. 70).
Valves out of adjustment. Adjust valve clearance (par. 60).
Broken valve spring. Notify ordnance personnel.
One or more cylinders misfiring. Inspect fuel supply (par. 66).
Air leaks in fuel system. Inspect for loose connections
(par. 71).
67
to
to
to
to
to
to
to
TM 9-787A
58
HEAVY TRACTOR Ml
Probable Cause
Clogged fuel filters.
Fuel lines cracked.
Surging governor.
(2) Engine Runs Hot.
Insufficient cooling water supply.
Radiator tubes clogged.
Rotted hoses.
Radiator fins clogged.
Fan belts loose or broken.
Water pump inoperative.
Thermostat stuck in closed posi-
tion.
Lack of oil pressure.
Carbon accumulation in engine.
Radiator shutter closed.
Probable Remedy
Replace filter elements (par. 68).
Replace lines (par. 71).
Bring engine up to operating tem-
perature; check for binding in
governor linkage.
Check water in radiator.
Clean radiator (par. 77).
Replace hoses (par. 79).
Blow chaff, etc., out of fins (par.
77).
Adjust or replace (par. 80).
Replace water pump (par. 75).
Replace (par. 78).
Notify ordnance personnel.
Notify ordnance personnel.
Open shutter.
(3) Loss OF Power.
Insufficient fuel.
Injectors out of time.
Injectors not equalized.
Governor out of adjustment.
Butterfly valve out of adjustment.
Air cleaner plugged.
Port holes in cylinder liners
plugged.
Burned valves.
Defective fuel pump.
Check fuel system.
Time injectors (par. 70).
Equalize injectors (par. 70).
Notify ordnance personnel.
Notify ordnance personnel.
Clean air cleaner (par. 73).
Notify ordnance personnel.
Notify ordnance personnel.
Replace (par. 69).
(4) Black Smoke from Exhaust.
Poor grade of fuel.
Air cleaner improperly serviced.
Muffler plugged.
Hand hole cover loose or gaskets
blown.
Precleaners plugged.
Port holes in cylinder liners
clogged.
Air box drain tube plugged.
Injectors out of time.
Change to better fuel.
Check air cleaners (par. 73).
Replace muffler (par. 62).
Tighten cover or replace gasket.
Remove and clean (par. 72).
Notify ordnance personnel.
Remove and clean.
Time injectors (par. 70).
68
TM 9-787A
58-59
ENGINE
Probable Cause Probable Remedy
Injectors not equalized. Equalize injectors (par. 70).
Defective injector. Replace injector (par. 70).
Valves out of adjustment. Adjust valve clearance (par. 60).
Poor compression. Notify ordnance personnel.
(5) Blue Smoke FROM Exhaust.
Insufficient fuel to injectors. Check fuel system (pars. 66 and
68).
Lubricating oil entering combus- Notify ordnance personnel.
tion chamber.
Injectors not equalized. Equalize injectors (par. 70).
(6) Engine Detonates (Knocks).
Injectors out of time. Time injectors (par. 70).
Injectors not equalized. Equalize injectors (par. 70).
Faulty injector. Replace injector (par. 70).
Damaged main or connecting rod Notify ordnance personnel.
bearings.
Incorrect valve clearance. Adjust valve clearance (par. 60).
Lubricating oil entering combus- Notify ordnance personnel.
tion chamber.
59. ROCKER ARM ASSEMBLY.
a. General. There are three rocker arms for each cylinder. The two
outer arms operate the exhaust valves and . the center rocker arm
operates the injector. The three rocker arms for each cylinder operate
on a single shaft, supported by two brackets. A special Va-inch hollow
cap screw holds each bracket to the cylinder head. The removal of
these two cap screws permits the brackets to be removed from the shaft
and the shaft to be removed from the rocker arms. The rocker arms
may then be laid back, giving access to the injector and valve assemblies.
The rocker arm assemblies may be replaced by the using arm personnel
if they are broken or worn.
b. Removal of Rocker Arm Assembly.
WRENCH, open-end, yie-in. (2) WRENCH, open-end, %6-in.
WRENCH, open-end, Va-in. WRENCH, socket, Va-Iti.
( 1 ) Remove Precleaners and Hood. Refer to paragraph 70 d and
figures 61 and 62.
(2) Remove Rocker Arm Cover. Unscrew the two hand screws
holding rocker arm cover to cylinder head and lift off cover.
69
TM 9-787A
59
HEAVY TRACTOR Ml
(3) Loosen Push Rod Lock Nuts.
WRENCH, open-end, Va-in.
Loosen nuts urjderneath clevis on push rods.
(4) Remove Injector Fuel Lines.
WRENCH, open-end, 1/2 -in.
Remove the fuel line connectors at both ends of injector fuel lines
and remove lines. Place shipping caps on fittings from which lines were
removed.
RA PD 17606
Figure 33— In/ector Fuel Line Removed
(5) Remove Rocker Shaft Brackets.
WRENCH, socket, y4-in.
Remove the two cap screws holding the rocker arm assembly to cylin-
der head and remove brackets.
(6) Remove Shaft. Remove shaft by sliding it out of rocker arms.
(7) Remove Rocker Arm Assemblies. Unscrew push rods from
clevises and remove rocker arms.
c. Installation.
GAGE, feeler
GAGE, injector timing
SCREWDRIVER
WRENCH, open-end, 1/4 -in.
WRENCH, open-end, Vz-in.
WRENCH, socket, ¥4 -in.
70
TM 9-787A
59
ENGINE
RA PD 17619
Figure 34— Removing Cap Screws from Rocker Arm Brackets
( 1 ) Install Rocker Arms on Push Rods. Screw the push rods into
the rocker arm clevis so that the end of the rod is flush with the top of
the threaded part of the clevis. NOTE: This is very important because
of the small clearance between the valve head and the top of the piston
when the piston is at the top of its stroke. It is possible for the piston
to strike the head of the valve, resulting in considerable damage, if
rocker arm is not screwed down far enough. The injector rocker arm
has a hardened ball stud and ball seat which form a universal joint.
(2) Slide Shaft Through Rocker Arms. If the original shaft is
used, turn the side having the greatest evidence of wear up.
(3) Install Brackets.
WRENCH, socket, y4-in.
Place the brackets on the shaft, smooth side towards rocker arms, and
draw the long cap screws down firmly. As the brackets are tightened
down, hold the brackets together, allowing only slight clearance between
the rocker arms and brackets. A total of 0.003-inch to 0.006-inch clear-
ance is sufficient.
(4) Install the Injector Fuel Lines.
WRENCH, open-end, 1/2-in.
Remove the shipping caps and install the fuel lines.
71
TM 9-787A
59-60
HEAVY TRACTOR Ml
RA PD 56464
Figure 35— Installing Rocker Arm
(5) Adjust Valve Clearance and Timing and Equalize Injec-
tor. See paragraph 60 for valve clearance adjustment, and paragraph
70 for injector timing and equalizing.
60. VALVE CLEARANCE.
a. GeneraL Correct valve clearance is important because of high
compression pressure developed in a Diesel engine. Too little clearance
causes a loss of compression, "missing," and eventual burning of the
valves and valve seats. Too much clearance results in noisy engine op-
eration. The correct valve clearance is 0.010-inch at operating tempera-
ture. The valve clearance is adjusted by turning the push rod in the
rocker arm clevis, which changes the length of the rod. Turn the push
rod to the left to decrease valve clearance (lengthen rod), and to the
right to increase clearance (shorten rod). Follow the steps outlined
below to set the valve clearance correctly.
b. Adjustment.
GAGE, feeler WRENCH, open-end, Va-in.
WRENCH, open-end, 5/, g-in.
(1) Rotate Engine Until Injector Is at Bottom of Stroke.
Rotate the engine with the starting motor until the injector plunger is
fully depressed (injector rocker arm down).
72
TM 9-787A
60-61
ENGINE
(2) Adjust Clearance Between Rocker Arm and Push Rod.
GAGE, feeler
WRENCH, open-end, %6-in.
WRENCH, open-end, Va-in.
Use the 0.010-inch feeler gage and adjust each push rod until the gage
will just pass between the valve stem and the rocker arm.
RA PD 17491
figure 36— Valve Clearance Adjustment
(3) Tighten Lock Nut.
WRENCH, open-end, %a<n. WRENCH, open-end, Va-in.
Hold push rod and tighten lock nut. Check again to see if 0.010-inch
feeler gage can be inserted between the valve stem and rocker arm. A
slight drag should be felt on feeler gage.
(4) Repeat above steps for each cylinder.
61, GOVERNOR.
a. Description. The governor is of the mechanical, flyball or fly-
weight type. Its purpose is to control engine idling speed and to limit
maximum engine speed under the variable load requirements.
b. Many governors are adjusted unnecessarily because of failure to
realize that, while irregularities in engine performance may result from
faulty governors, they more often are due to other causes. A governor,
when correctly adjusted, will seldom require attention.
73
TM 9-787A
61-62
HEAVY TRACTOR Ml
c. The using arm personnel should not attempt any adjustment or
replacement of the governor. All other possible causes of irregular en-
gine performance should be eliminated first, and if the governor is still
suspected as the cause, report it to the ordnance personnel.
62. EXHAUST MANIFOLD AND MUFFLER.
a. Description. The exhaust manifold is in one section and is held
to the cylinder head by five %(j-inch studs, nuts, and special washers.
The muffler is bolted to the manifold with four 1/2 -inch cap screws and
lock washers and supported at each end by supports from the cylinder
block end plates. There is also a muffler support strap between the ex-
haust manifold and the muffler.
b. Trouble Shooting.
( 1 ) Loud Exhaust.
Probable Cause
Gasket blown.
Holes in muffler.
Break in manifold.
Broken supports.
Probable Remedy
Replace gasket.
Replace muffler.
Replace manifold.
Replace supports.
RA PD 17708
Figure 37 —Removing Bolts from Muffler Clamp
74
TM 9-787A
62
ENGINE
WRENCH, socket, y4-in. with
extension
c. Removal.
WRENCH, open-end, %6-in.
WRENCH, socket, %Q-m.
WRENCH, socket, s/g-in.
(1) Remove Muffler Clamp.
WRENCH, open-end, % g-in. WRENCH, socket, % g-in.
Remove the four bolts from clamp around muffler.
(2) Remove Muffler.
WRENCH, socket, »/i,i-in. WRENCH, socket, %.in.
Remove the two cap screws holding muffler to front support, two
cap screws holding stack elbow to muffler, and the four cap screws hold-
ing muffler and elbow to rear support and manifold, and remove muffler.
Figure 38— Removing Muffler
RA PD 17710
(3) Remove Manifold.
WRENCH, socket, %-in. with extension
Loosen the nuts on stud bolts holding manifold to cylinder head and
lift manifold off the studs.
(4) Remove Muffler Supports.
WRENCH, open-end, 9/i ,j-in. WRENCH, socket, % „-in.
Remove the cap screws and nuts from bolts holding supports to
75
TM 9-787A
62
HEAVY TRACTOR Ml
RA PD 17712
Figure 39— Removing Exhaust Manifold
cylinder block end plates, and remove supports. NOTE: Because the
heat to which cap screws in the muffler are subjected causes them to
"seize" in the threads, it is advisable to leave the muffler supports at-
tached to the muffler and manifold, unless repair or replacement of
some of the parts is necessary. Remove the cap screws and nuts on
bolts holding the supports to the cylinder block end plate and remove
the muffler, exhaust manifold and supports as a unit.
d. Installation.
WRENCH, open-end, %8-in.
WRENCH, socket, %6-in.
WRENCH, socket, s/g-in.
WRENCH, socket, y4-in., with
extension
( 1 ) Install Manifold. Clean all old gaskets off manifold and head.
Remove the nuts and washers from stud bolts in head and place new
gaskets on studs. Shellac or grease is unnecessary. Place manifold on
studs and tighten all nuts evenly.
(2) Install Muffler Supports. Put supports in place and install
bolts, cap screws, and lock washers, but do not tighten nuts or cap screws.
76
TM 9-787A
62-63
ENGINE
(3) Install Muffler.
WRENCH, socket, ^10 -in.
WRENCH, socket, 3/4 -in.
Start cap screws with lock washers through front support and back
support and manifold.
(4) Tighten All Bolts.
WRENCH, socket, 'Vu-An. WRENCH, socket, 3/4 -in.
Tighten cap screws bolting muffler bracket to manifold, first. Then,
tighten all cap screws and nuts in muffler supports.
(5) Install Muffler Clamp.
WRENCH, socket, '/Ki-in.
Place clamp around muffler body and manifold, install bolts, lock
washers, and nuts, and tighten.
63. REMOVAL OF ENGINE
a. Equipment.
CHAIN HOIST
HAMMER, 2-lb
PLIERS
PUNCH, large
PUNCH, small
ROPE
SCREWDRIVER, 10-in.
WRENCH, 1/2 -in.
WRENCH, %.in. (2)
WRENCH, Jy,,j-in.
WRENCH, 1-in.
FROM TRACTOR.
WRENCH, box, %,,
-in. with
90 deg offset
WRENCH, open-end.
%-in.
WRENCH, open-end.
7i«-in.
(2)
WRENCH, open-end.
'Kfi-in.
WRENCH, open-end.
Ys-in.
WRENCH, open-end.
iyi«-in.
WRENCH, open-end.
%-in.
WRENCH, socket, %
-in.
b. Procedure.
( 1 ) Drain Cooling System. Open drain cocks in lower connector
elbow and water pump.
(2) Remove Precleaners and Hood.
WRENCH, yi„-in. (2)
WRENCH, open-end, % ,,-in.
Loosen clamp bolts (y^,;-in. wrenches) and lift precleaners off pre-
cleaner extension tubes. Loosen bolts at each corner of hood ('Xo-in.
wrench), pry bolts out of clips and lift hood off over exhaust tail pipe
and precleaner elbows (figs. 61 and 62).
(3) Remove Both Front Fenders.
WRENCH, 3/4 -in. (2)
Remove four bolts in right fender' and three bolts and one cap
screw in left fender and remove fenders (fig. 74).
77
TM 9-787A
63
HEAVY TRACTOR Ml
(4) Remove Winch Drive Shaft Guard and Guard Support
Bracket.
WRENCH, % 6-in- WRENCH, 1-in.
WRENCH, 3/4 -in. (2)
Remove winch drive shaft guard by removing the three bolts at rear
of guard (%-in. wrenches) and three cap screws at front (%g-in.
wrench). Remove the two cap screws holding bracket to radiator shell
(1-in. wrench) and then remove bracket. Remove the two correspond-
ing cap screws on right side holding radiator shell to engine support.
(5) Disconnect Wires and Upper Radiator Hose.
SCREWDRIVER, 10-in. .
Disconnect ground terminal from battery post. Disconnect headlight
wires at connector. This connector can be found near generator. Loosen
lower clamp of top radiator hose and remove hose from thermostat
housing.
(6) Remove EngIne Support Bottom Cover.
WRENCH, '/s-in.
Remove the six cap screws holding cover to engine support. It may
be necessary to pry cover from support (fig. 88).
(7) Disconnect Lower Water Connection.
WRENCH, 1/2 -in.
Remove the two cap screws holding connection to oil cooler inlet.
(8) Remove Radiator Grille.
CHAIN HOIST WRENCH, 1-in.
HAMMER, 2-lb WRENCH, socket, ysin. with
PUNCH, large 6-in. extension
ROPE
Remove the four nuts on each side from bolts holding grille to radia-
tor (%-in. wrench). Loosen the two remaining cap screws holding
radiator shell to engine support (1-in. wrench) and tilt top of radiator
back until radiator touches fan. Drive out the T-head bolts from which
nuts were removed (hammer, punch), taking care not to damage
threads, and lift out grille (rope, chain hoist). NOTE: The lower
bolts on left-hand side should be removed last, as grille will have to
be shifted to the left to allow this bolt to pass under flange on winch
drum.
(9) Remove Fan Assembly.
PLIERS WRENCH, y4-in.
Remove pin from radiator shutter control rod (pliers) and pull
top of radiator as far forward as possible. Remove the three cap screws
holding bracket of fan assembly (fig. 81) to balance weight cover of
engine (%-in. wrench), remove belts from pulley and lift out fan
assembly. Disengage shutter control rod, as radiator is lifted out.
78
TM
9-787A
63
ENGINE
E
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in
in
<
V.
O
at
o
c
I
o
V
h
3
79
TM 9-787A
63
HEAVY TRACTOR Ml
(10) Lift Out Radiator Assembly.
CHAIN HOIST WRENCH, 1-in.
Remove the two capscrews previously loosened on each side at
bottom of radiator shell (1-in. wrench). Place rope around radiator
under headlights. Lift out radiator assembly (chain hoist).
(11) Disconnect Control Rods. Disconnect throttle control shaft
lever to governor rod by removing cotter pin and yoke pin connecting
the rod to the governor. Disconnect shut-off bell crank to air shutter
shaft lever rod by removing cotter pin and yoke pin connecting the
rod to the air shutter shaft lever. Disconnect shut-off bell crank to
governor rod by removing cotter pin and yoke pin connecting the rod
to the governor.
(12) Disconnect Fuel Lines.
WRENCH, open-end, %-in. WRENCH, open-end, %-in.
Shut off fuel supply by closing fuel shut-off cock under tank. Dis-
connect fuel pressure gage line from fitting at top of third stage filter
(■Vi-in. and %-in. wrenches), taking care not to twist flexible hose.
Disconnect line from second stage to third stage filter (%-in. and ys-in.
wrenches). Disconnect flexible engine oil pressure line at union to
steel tubing on right side of cowl (-Vi-in. and Va-in. wrenches). Dis-
connect fuel pump discharge line from second stage filter (%-in.
wrench). Disconnect fuel pump inlet and fuel return lines from con-
nections under front of cowl on engine support (Vs-in. wrench).
(13) Remove Thermo Gage Tube.
WRENCH, open-end, ^ %cAn.
Loosen and remove thermo gage tube from rear end of water mani-
fold.
(14) Remove Air Intake Elbow.
CLOTH, large • WRENCH, o/ie-in.
SCREWDRIVER, 10-in,
Loosen front hose clamp (screwdriver) and remove four cap screws
holding elbow (%(i-in. wrench). Remove elbow. Stuff large cloth into
air intake housing to prevent any foreign matter from entering.
(15) Disconnect Air Heater Fuel Line.
WRENCH, opdn-end, 7io-in. WRENCH, open-end, %6-in.
(2)
Disconnect air heater fuel line at rear of check valve underneath air
heater (%e-in. wrenches). Remove clip and cap screw holding line to
cylinder block end plate CJ^e-in- wrench).-
(16) Remove Air Heater Cover and Disconnect Coil Wire.
WRENCH, 1/2-in. WRENCH, open-end, a/s-in.
Remove two cap screws holding air heater cover (Va-in. wrench),
80
ENGINE
TM 9-787A
63
RA PD 56393
Figure 41— Removing Thermo Gage Tube from Water
Outlet Manifold
Figure 42 -View Showing Wires, Lines, and Controls
to Be Disconnected
81
TM 9-787A
63
HEAVY TRACTOR Ml
remove cover, disconnect wire from bottom of coil ( %-in. wrench) and
reinstall cover ( Va-in. wrench).
(17) Disconnect Starting Motor.
PLIERS WRENCH, 3/4 -in.
Disconnect battery cable from starting motor switch terminal. Tape
end of battery cable to prevent its contacting metal. Lift ammeter and
electric trailer brake control wire from terminal. Disconnect the starting
motor control rod by removing cotter pin and pin (pliers) from the
starter lever.
(18) Disconnect Wire from Voltage Regulator.
SCREWDRIVER, 10-in.
Disconnect wire running from voltage regulator to ammeter.
(19) Remove Air Lines.
WRENCH, yie-in. WRENCH, open-end, Vs-in.
WRENCH, y2-in. WRENCH, open-end, '/g-in.
Disconnect the two air lines from fittings on top of air compressor
(%-in. and %-in. wrenches) and remove bolts from clip holding lines
to air compressor bracket CX^-in. and 1/2 -in. wrenches).
(20) Engage Master Clutch. The master clutch must be engaged
so that throw-out bearing will clear clutch shaft when engine is moved
ahead to be lifted out of tractor.
(21) Remove Clutch Inspection Hole Cover.
PLIERS WRENCH, y4-in.
Remove two cap screws and lift off floor plate over inspection hole
cover (%-in. wrench). Remove four cap screws from cover over master
clutch inspection hole (%-in. wrench). Remove cover, pull cotter pin
(pliers) and remove yoke pin from end of master clutch control rod
(fig. 114).
(22) Remove Nut from Release Bearing Lubricating Tube.
WRENCH, iyir,-in.
Remove nut from lubricating tube on top of clutch housing and push
grease tube down into clutch compartment. Prevent tube from turning
or twisting while removing nut (fig. 43).
(23) Disconnect Engine from Spacer.
PUNCH, small WRENCH, box, %6-in., with
90 deg offset
Remove the ten cap screws holding engine to spacer. NOTE: The
two bottom cap screws may be most easily removed with a 90-degree
offset, box socket wrench. The offset wrench can be placed between the
flywheel housing and equalizer spring to remove the cap screws. Turn
wrench with punch through opposite end of wrench.
82
ENGINE
TM 9-787A
63
RA PD 56394
Figure 43— View Showing Location of Engine-to-Spaeer Cap Screws
Figure 44— Removing Bolls from Front Engine Hanger
83
TM
9-787A
63
HEAVY TRACTOR Ml
(24) Remove Bolts from Front Engine Hanger.
WRENCH, yg-in. WRENCH, i-ynrin.
Remove the two bolts from the front engine hanger (ys-in. and
^%,[-in. wrenches), Hft motor sHghtly, and take out the shims from be-
tween support and hanger.
(25) Lift Engine from Tractor.
CHAIN HOIST ROPE
Engine can now be removed by a chain hoist and rope connected to
lifter brackets. Raise engine high enough to take weight off engine sup-
ports; then slide engine forward far enough so that master clutch throw-
out bearing clears end of clutch shaft. Engine may then be lifted from
tractor.
figure 4S — Lifting Engine front Tractor
84
TM 9-787A
64
ENGINE
64. INSTALLATION OF ENGINE IN TRACTOR.
a. Before installing engine back into tractor, wash dirt and grease
from the engine support and master clutch compartment. At the same
time, inspect the engine support assembly, engine spacer, and master
clutch compartment and assemblies included in them, and if any repair
work is necessary on them, do it before engine is installed. Check engine
spacer and engine support bolts to see that all are tight and none missing.
Check bolts holding winch assembly to engine support, tighten or re-
place them if necessary. Also inspect wiring and fuel lines on tractor
for necessary repairs or replacement.
b. Equipment.
BAR, pry WRENCH, open-end, Ys-in.
CHAIN HOIST WRENCH, open-end, yio-in.
GAGE, injector timing WRENCH, open-end, Va-in.
PLIERS WRENCH, open-end, %8-in.
ROPE (2)
SCALE or RULER WRENCH, open-end, s/g-in.
SCREWDRIVER, 8-in. WRENCH, open-end, ^Vu-An.
SCREWDRIVER, 10-in. WRENCH, open-end, %-in.
WRENCH, 1-in. WRENCH, open-end, %-in.
WRENCH, box socket, "/le -in., WRENCH, open-erld, i^ic-in.
with 90 deg offset WRENCH, socket, %o-in.
WRENCH, engine cranking WRENCH, socket, Ya-in., with
WRENCH, fan adjusting 6-in. extension
WRENCH, open-end, %6-m. WRENCH, socket, 2/4 -in.
c. Procedure.
( 1 ) Lower Engine into Place.
CHAIN HOIST ROPE
NOTE: Master clutch must be engaged in order to install engine.
Using chain hoist and rope, lower engine into position until the hole
in clutch release bearing carrier lines up with end of clutch shaft. Start
engine back onto shaft.
(2) Line Up Splines.
WRENCH, engine cranking
Line up the splines on the clutch shaft with the splines in driven
member of master clutch. Crankshaft will have to be turned to do
this, using cranking wrench. Line up sliding blocks on release bearing
carrier with slots in throw-out yoke. Push engine back until sliding
blocks engage yoke and clutch shaft enters driven member hub.
(3) Connect Engine to Spacer.
WRENCH, box socket, %6-in., WRENCH, socket, %o-in.
with 90 deg offset
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HEAVY TRACTOR Ml
Start the ten %- x 2-inch cap screws with lock washers holding
flywheel housing to engine spacer (two %6-in- wrenches). Tighten them
securely before removing chain hoist and chain.
(4) Install Shims Under Front Engine Hanger.
CHAIN HOIST WRENCH, %-in.
ROPE WRENCH, ^%^-m.
Use shims taken out when engine was removed. Crowd as many
shims as possible without raising front of engine between front engine
hanger end and engine support. Then, raise front of engine with chain
hoist and add one more shim to each side (shims are %2-in. thick).
Install the two V&- x 2-inch bolts with lock washers holding engine
hanger and shims to engine support bracket (fig. 44).
(5) Connect Release Bearing Lubricating Tube.
WRENCH, open-end, ^ y, ,,-in. WRENCH, open-end, i % ^-in.
Insert release bearing lubricating tube through hole in spacer and
secure with %-inch jam nut (fig. 43).
(6) Connect Inner Clutch Rod.
PLIERS
Connect inner clutch rod to sublever with pin and cotter pin.
(7) Adjust Master Clutch and Clutch Brake.
. BAR, pry WRENCH, s/io-in.
PLIERS WRENCH, 3/4 -in. (2)
SCALE or RULER
Refer to section XVIII.
(8) Install Master Clutch Inspection Cover.
WRENCH, socket, 3/4-in.
Install master clutch inspection cover and gasket with four V2- x
1 Vi-inch cap screws with lock washers.
(9) Install Air Intake Elbow.
SCREWDRIVER, 10-in. WRENCH, '^.rin.
Remove large cloth from blower intake. Install air intake elbow
and gasket to top of air intake housing with four %- x 1-inch cap
screws and lock washers (%B-in. wrench). Slide hose coupling into
position on air cleaner outlet pipe and tighten clamps (screwdriver).
(10) Connect Control Rod.
PLIERS
Connect shut-ofif bell crank to air shutter shaft lever rod by installing
yoke pin and cotter pin connecting the rod to the air shutter shaft
lever. Connect shut-off bell crank to governor rod by installing yoke
pin and cotter pin connecting the rod to the governor.
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ENGINE
(11) Connect Air Lines.
WRENCH, open-end, %-in. WRENCH, open-end, %-in.
Connect air line from air reservoir to left side of compressor ( '/s-in.
wrench). Connect air governor line to compressor on right side (%-in.
wrench).
(12) Connect Starting Motor.
PLIERS WRENCH, 3/4 -in.
Connect the starting motor control rod to starter lever with pin and
cotter pin (pliers). Connect battery cable, electric trailer brake cable,
and ammeter wire to starting motor switch terminal (y4-in. wrench).
(13) Connect Air Heater.
WRENCH, 1/2 -in. WRENCH, open-end, % e-in.
WRENCH, open-end, %-in. (2)
WRENCH, open-end, '',\^i-\n.
Connect air heater fuel line at check valve at bottom of unit (two
"-'i,;-in. wrenches). Connect coil wire to coil terminal (ys-in. wrench).
Install air heater cover with two ^y- x 2%-inch cap screws with lock
washers (12-in. wrench). Install air heater fuel line clip to flywheel
housing on bolt already in housing (^i(j-in. wrench).
(14) Connect Wires to Voltage Regulator.
SCREWDRIVER, 10-in.
Connect wire from wiring harness to voltage regulator terminal and
tighten screw.
(15) Connect Fuel Lines.
WRENCH, open-end, y4-in. WRENCH, open-end, %-in.
Connect fuel pump inlet line to connection at right side of cowl on
engine support (% and %-in. wrenches). Connect fuel return line to
fitting on right side of cowl on engine support (% and Vs-in. wrenches).
Install the fuel pump discharge line by connecting to fuel pump and
second stage fuel filter (^g-in. wrench). Install fuel line between second
stage fuel filter and third stage fuel filter ('/s-in. wrench). Connect fuel
oil pressure line to third stage fuel filter ( V&-in. wrench).
(16) Connect Lubricating Oil Pressure Gage Line.
WRENCH, open-end, y»-in.
Connect the lubricating oil pressure gage line to connection at right
rear of engine. Install clip holding gage line to the line between the fuel
pump and secondary filter.
(17) Connect Throttle Control Rod.
PLIERS
Connect throttle control rod to control bracket arm on the cowl with
yoke pin and cotter pin.
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(18) Install Thermo Gage Tube.
WRENCH, open-end, n/i.rin.
Install thermo gage tube in rear of water manifold and tighten jam
nut (fig. 41).
(19) Lower Radiator into Position.
CHAIN HOIST WRENCH, 1-in.
ROPE
Lower radiator assembly into position on front of engine support.
Start the two front lower %- x 1%-inch cap screws with lock washers
holding radiator to engine support, but do not tighten. Remove chain
hoist and rope.
(20) Install Fan Assembly and Connect Radiator Shutter
Control Rod.
PLIERS WRENCH, fan adjusting
WRENCH, 3/4 -in.
Tilt radiator forward, lay belts in fan pulley and install fan assembly
on balance weight cover with three V2- x 2V4-inch cap screws with lock
washers (%-in. wrench). Adjust belts so one side of belt can be de-
pressed 1 inch between pulley (%-in. wrench and fan adjusting wrench).
Install pin through control rod and radiator shutter lever and secure with
cotter pin (pliers).
(21) Install Radiator Grille.
HAMMER, 2-lb WRENCH, socket, Vs-in., with
PUNCH, long 6-in. extension
Tilt radiator back until it touches fan. Set grille in position and install
the eight T-head bolts with lock washers holding radiator grille to shell
(punch, hammer, %-in. wrench). Install lower left-hand bolt first as
grille will have to be shifted to the left so that this bolt will pass flange
of winch drum.
(22) Connect Top Radiator Hose. Shellac lower end of hose and
place over thermostat housing outlet. Fasten clamp.
(23) Install Cap Screws Holding Radiator.
WRENCH, 1-in.
Install the two remaining V4- x 1%-inch cap screws with lock washers
on right side of radiator. Do not tighten.
(24) Install Winch Drive Shaft Guard Bracket.
SCREWDRIVER, 10-in. WRENCH, 1-in.
Install bracket in position and install two %- x 2-inch cap screws with
lock washers through it into engine support on left side of radiator.
Tighten radiator bolts on both sides (1-in. wrench). Tighten hose clamps
on top hose (screwdriver).
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ENGINE
(25) Install Lower Water Connection.
WRENCH, 1/2 -in.
Shellac new gasket to oil cooler inlet and install lower water connec-
tion with two %e- X 1-inch cap screws with lock washers.
(26) Install Engine Support Cover.
WRENCH, 7/8-in.
Install engine support bottom cover and secure with six %. x lV2-inch
cap screws with lock washers. See that crankcase drain plug is tight in
place.
(27) Connect Headlight Wires. Connect headlight wires at con-
nector near generator.
(28) Fill Cooling System. Close drain cocks and fill cooling system
with water, or, if it is below freezing, antifreeze solution. Remove pipe
plug in thermostat housing while filling system. Install plug when water
runs out the hole and finish filling radiator.
(29) Fill Engine and Air Compressor Crankcases with Oil. Fill
engine crankcase to "FULL" mark on oil level bayonet gage with OIL,
engine, seasonal grade (13 qt). Fill air compressor crankcase to level of
filler plug with engine oil. See lubrication charts for specifications
(sec. IV).
(30) Equalize Injectors.
GAGE, injector timing WRENCH, open-end, Va-in.
WRENCH, open-end, %6-in-
Injectors must be equalized at this time. Remove rocker arm cover,
if it has been installed, and follow procedure outlined in paragraph 70.
(31) Install Front Fenders.
WRENCH, 3/4 -in. (2)
Install right fender with four 1/2- x IVi-inch bolts with lock washers.
Install left fender with three V2- x IVi-inch bolts and one cap screw
with lock washer. Tighten bolts and cap screws.
(32) Install Winch Drive Shaft Guard.
WRENCH, %6-in. (2) WRENCH, 3/4-in. (2)
Place winch drive shaft guard in place. Install three %- x 1-inch cap
screws with lock washers holding guard to front bracket (%6-in. wrench).
Install two %- X IVi-inch bolts (two %6-in. wrenches) and one Va- x
IVi-inch bolt with lock washers (two %-in. wrenches) holding rear end
of guard to left rear fender.
(33) Start Engine. Open fuel shut-off cock under tank. Fasten
ground terminal connection to battery post. Check all wires, fuel lines,
and controls to be sure they are all connected and tight, and start engine.
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It is advisable to fill the second and third stage fuel filters to save crank-
ing the engine with starting motor for fuel pump to fill them, although
it is not necessary. After engine starts, check all fuel, oil, and water con-
nections and fuel and oil filters for leaks. Observe fuel and lubricating
oil pressure gages to see that they are registering the correct pressures.
(34) Install Hood.
WRENCH, open-end, % e-i"-
Install hood over precleaner elbows and exhaust tail pipe, insert
corner hold-down bolts in clips, and tighten bolts.
(35) Install Precleaners.
WRENCH, y^-in. (2)
Install precleaners on air intake elbows and tighten clamp bolts.
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Section XII
FUEL AND AIR SYSTEM
Paragraph
General 65
Fuel supply tank 66
Sediment sumps 67
Fuel filters 68
Fuel pump 69
Injectors 70
Fuel lines and connections 71
Precleaners 72
Air cleaner 73
65, GENERAL.
a. The fuel system consists of a fuel tank, sediment sumps, fuel
pump, fuel filters, fuel lines and injectors. The 156-gallon supply tank
is equipped with sediment sumps, drains, and a fuel shut-off valve. The
first stage, or primary filter assembly, consists of two filters, exactly
alike, mounted on a bracket bolted to the transmission case. There are
also two other filters: the second stage filter, fastened on the front of the
cowl, and the third stage filter, bolted to the engine. The fuel pump is
ENGINE FUEL MANIFOLDS
INJECTORS
-Tiiii
o o
3RD STAGE FUEL
FILTER
2ND STAGE FUEL
FILTER
FUEL PUMP
ST STAGE FUEL FILTERS
SEDIMENT SUMPS
RA PD 17515
Figure 46— Fuel System Diagram
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bolted to the rear of the blower and is driven by the lower blower rotor
shaft.
b. The fuel is drawn from the bottom of the fuel tank and through
the first stage filters by the fuel pump. The fuel is then forced, under
about 25 pounds pressure, through the second and third stage filters to
the lower fuel manifold on the side of the cylinder head. From this mani-
fold the fuel flows, under pressure, to the injectors, through a porous
bronze filter located in the injector. The surplus fuel leaves the injector
through a similar porous bronze filter and returns through the return
or upper fuel manifold and fuel return line to the fuel tank. This con-
tinual circulation of fuel oil helps to cool the injectors, warms up the
fuel, and eliminates air pockets in the fuel system.
66. FUEL SUPPLY TANK.
a. Description. The fuel tank is located at the rear of the tractor
and has a capacity of 156 U. S. standard gallons. Care should be taken,
when filling the tank with fuel, that all hoses, funnels, or containers
used are clean to prevent dirt from entering and clogging the fuel lines
and filters.
b. Two sediment sumps on the bottom of the tank (fig. 24) are
provided to allow the operator to drain out, with a minimum waste of
fuel, the dirt and water which settles to the bottom. Dirt and water
will settle out of the fuel into these sumps and can be drained out.
Drain cocks on these sumps should be opened daily, preferably after
the tractor has stood for an hour or more, or overnight. In freezing
weather, it is doubly important to drain the water from the sediment
sumps and filters to prevent freezing and damage due., to freezing.
c. Maintenance. The tank should be drained and flushed out peri-
odically with clean fuel oil whenever an accumulation of rust or dirt
is evident. To do this, the tractor should be on level ground. Remove
the two sediment sumps from the tank and poUr about 10 gallons of
clean fuel oil into the tank and let it drain out, flushing the dirt and
rust with it. If a pressure fuel hose is available, flushing may be done
by inserting the hose through the holes in the bottom of the tank
where the sediment sumps were removed. Use new gaskets and shellac
both sides of gasket when installing the sediment sumps back on the
tank.
67. SEDIMENT SUMPS.
a. The purpose of the sediment sumps (fig. 24) has been explained
in paragraphs 66 b and c.
b. Removal.
CONTAINERS, fuel WRENCH, socket, %6-in., with
extension
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FUEL AND AIR SYSTEM
(1) Drain Tank. Drain fuel from tank into clean containers.
(2) Remove Sumps. Remove three cap screws and lock washers
from each unit and remove the sediment sumps.
(3) Clean Off Old Gaskets. Clean old gaskets off fuel tank be-
fore installing new sediment sumps.
c. Installation.
SHELLAC WRENCH, socket, % ,i-in., with
extension
( 1 ) Shellac New Gaskets to Sumps.
SHELLAC WRENCH, socket, %6-'n., with
extension
(2) Install Sumps. Install sumps with cap screws and lock washers.
68. FUEL FILTERS,
a. General. The circulation of fuel oil through the injectors in this
engine helps keep the injectors cool. The fuel pump circulates ap-
proximately 25 gallons of fuel per hour through the injection system.
If this quantity is allowed to decrease and get too low, there is a
possibility of serious damage to the injectors because of overheating.
As the fuel filters begin to plug up, the quantity of fuel circulating
through the injectors becomes less. It may be reduced to the point
where the injectors are becoming dangerously overheated, even though
this flow may be sufficient to keep the engine operating normally.
Therefore, proper performance of the engine does not necessarily mean
that enough fuel is being circulated. For this reason, the fuel filtering
system should be checked and the filter elements replaced, if necessary,
at the first indication of any deviation from normal fuel oil pressure.
All fuel filters are of the replaceable element type. A good indication as
to about how often it will be necessary to replace filter elements will
be given by the length of time the first two or three elements used
operate satisfactorily. That is, if the filters plug up on an average of
every 400 hours for the first two or three times, the fuel filters should
be changed, as an item of routine service, every 400 hours of operation
thereafter, without waiting for a drop in fuel pressure. The length of
time that the fuel filter elements will operate, depends upon the type
and kind of fuel oil being used and also on how clean the fuel oil is
kept. Change the filter elements in the fuel filters after a reasonable
number of hours of operation, even though they are not completely
plugged up, in order to safeguard the injection system.
b. Maintenance.
(1) Normal fuel pressure is frojn 20 to 30 pounds on the gage at
operating engine speed. CAUTION: Do not operate when the fuel
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pressure is not within this range. When pressure drops to below 20,
proceed as follows:
(a) Drain sediment sump under fuel tank of all water and sedi-
ment.
(b) Remove both first stage fuel filter elements and test fuel line
from the tank to these filters to be absolutely sure that it is free and
open. If necessary, replace the first stage filter elements with new
ones. When installing them, make certain that the filter and gasket are
in their proper place to prevent leakage. When starting engine after
replacing this filter, it may be necessary to open drain at bottom of
filter to allow air to escape before fuel will start to circulate through
fuel system.
(c) Start engine and check to see whether fuel oil pressure comes
up to normal. If not, stop the engine and replace element in second
stage filter. Check fuel lines for obstructions and leaks and again start
engine to determine whether fuel oil pressure comes up to normal.
(d) If fuel oil pressure is still below normal, replace element in third
stage fuel filter. If all fuel line connections are tight, eliminating all
possibility of air leaks, and pressure still does not come up to normal
after above procedure, the fuel pump will have to be removed for
repair or rebuilding and a new pump installed.
(2) If the fuel pressure is within the normal range and the opera-
tion of engine indicates that insufficient fuel is being supplied to the
injectors, proceed as follows to locate the trouble:
(a) Check for obstructions in fuel lines and fuel manifold carrying
fuel to the injectors. Also see that return fuel manifold and return
fuel line to tank are not restricted in any way. To check the return
flow, remove fuel tank cap and look into tank. When the engine is
idling, there should be an ample flow of fuel into the tank from the
return line.
(b) If no restriction is found in any part of fuel system as outlined
in step (1) in this paragraph, it is likely that the porous bronze filters
in the injectors are plugged, and the injectors will have to be removed.
(c) Replace, time, and equalize the injectors.
(d) Adjust exhaust valve clearance (pars. 60 and 70).
c. First Stage Filter Assembly.
( 1 ) Description. The first stage filter assembly consists of two indi-
vidual filters suspended on a bracket bolted to the transmission case.
A fuel line from the supply tank leads to this assembly and another leads
from the assembly to the fuel pump. Cotton-wound elements are used in
these filters.
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FUEL AND AIR SYSTEM
RA PD 17707
Figure 47— First Stage Filter Assembly
(2) Removal.
WRENCH, open-end, Vs-in.
(a) Disconnect Fuel Lines.
WRENCH, open-end, Vs-in.
Close fuel shut-off valve at tank and disconnect the fuel lines from
both inlet and outlet side of filter assembly.
(b) Remove Assembly from Tractor.
WRENCH, open-end, ^s-in.
Remove the two cap screws holding bracket to tractor transmission
case and remove assembly.
(3) Disassembly.
WRENCH, open-end, %6-in.
WRENCH, open-end, %-in.
WRENCH, socket, %6-in-
WRENCH, socket, %6-in.
95
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(a) Remove Filter Cups.
WRENCH, socket, "/ifi-in.
Remove the four cap screws from each filter head and remove filter
cups.
(b) Remove Filters from Bracket.
WRENCH, open-end, %6-in. WRENCH, socket, "/ic-in.
WRENCH, open-end, %-in.
Disconnect flexible fuel lines from filters, remove the two bolts holding
each filter to bracket and remove filters from bracket.
(4) Maintenance. Remove the dirty or clogged element and clean
cup thoroughly with clean fuel oil. Replace old element with new one.
NOTE: Do not attempt to clean dirty or clogged elements. It is not
necessary to remove the entire assembly to replace filter elements. The
element can be changed by merely removing the filter cups from the two
filter heads of the assembly, leaving balance of assembly installed.
(5) Reassembly.
WRENCH, open-end, yig-in. WRENCH, open-end, %-in.
WRENCH, open-end, ^e-in. WRENCH, socket, %(i-in.
(a). Install Filter Heads.
WRENCH, open-end, %fi-in. WRENCH, socket, %o-in.
Clamp bracket in vise, if vise is available, and install filter clamp rings
to bracket with two bolts each.
(b) Install Filter Cups.
WRENCH, socket, Vie-in.
Bolt the cups to the filter heads with four cap screws, each using new
gaskets. Shellac both sides of gaskets.
(c) Connect Fuel Lines Between Filters.
WRENCH, open-end, '/s-in.
Place connectors of the flexible fuel lines on fittings, as shown in fig-
ure 47, and tighten them.
(6) Installation.
WRENCH, open-end, '/s-in.
(a) Install Assembly on Tractor.
WRENCH, open-end, '/g-in.
Install the assembly on the transmission case with the two cap screws.
(b) Connect Fuel Lines to Filter Assembly.
WRENCH, open-end, '/g-in.
Connect the fuel lines to each end fitting of filter assembly; open fuel
shut-off valve under fuel supply tank and inspect for leaks.
d. Second Stage Fuel Filter.
( 1 ) Description. This filter is located in front of the cowl and held
in two mounting bands bolted to cowl.
96
TM 9-787A
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FUEL AND AIR SYSTEM
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TM 9-787A
68
HEAVY TRACTOR Ml
RA PD 17612
Figure 49— Removing First Stage Filter Cup
(2) Removal.
WRENCH, open-end, %8-in.
WRENCH, open-end, s/s-in.
WRENCH, open-end, Vs-in.
WRENCH, socket, %6-in.
(a) Disconnect Fuel Lines.
WRENCH, open-end, Vs-in. WRENCH, open-end, ys-in.
Disconnect both inlet and outlet fuel lines.
(b) Remove Filter from Cowl.
WRENCH, open-end, %6-in. WRENCH, socket, %6-in.
Remove the four bolts holding mounting bands to cowl and remove
filter assembly.
(3) Disassembly.
WRENCH, open-end, Vi-in.
(a) Remove Mounting Band Bolts.
WRENCH, open-end, Vi-in.
Remove the bolts through mounting bands and slide bands oft filter
body.
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FUEL AND AIR SYSTEM
RA PD 17633
Figure 50— Disconnecting fuel Line from Second Stage Filter
(b) Remove Filter Cover.
Loosen and remove cover hold-down screw, clamp, and cover.
(c) Lift Out Filter Element.
Lift element from filter.
(4) Maintenance. Wash filter case out with clean fuel oil before
installing new element. See that drain cock is not clogged. This drain cock
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TM 9-787A
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HEAVY TRACTOR Ml
RA PD 17643
Figure 51— Removing Second Stage Filter Assembly
should be opened every day to drain sediment and water out of filter.
NOTE: To replace element only, the filter assembly should be left
installed on the tractor and only the hold-down clamp and cover
removed.
(5) Reassembly.
WRENCH, open-end, Va-in.
(a) Install Element in Filter.
(b) Install Cover. Place new gasket and cover on filter and tighten
cover with hold-down clamp and screw.
(c) Install Mounting Bands on Filter. Place bands on filter and install
bolts through bands, leaving nut loose.
(6) Installation.
WRENCH, open-end, Vz-in. WRENCH, open-end, Vs-in.
WRENCH, open-end, %6-in- WRENCH, socket, %«-in.
(a) Install Filter Assembly on Cowl. Install bolts through mounting
bands and cowl, and start nuts.
(b) Tighten Mounting Band Bolts.
WRENCH, open-end, 1/2-in.
(c) Tighten Bolts Holding Filter Assembly.
WRENCH, open-end, %o-in- WRENCH, open-end, %-in.
100
TM 9-787A
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FUEL AND AIR SYSTEM
RA PD 17642
Figure 52— Removing Second Stage Filter Element
(d) Connect Fuel Lines. Connect lower fuel line, fill the filter with fuel
(this will save cranking engine with starter to pump fuel to fill filter)
and connect upper fuel line.
(e) Check for Leaks. Start engine and check for leaks.
e. Third Stage Fuel Filter.
(1) General. The fuel leaving the second stage filter passes into and
through the third stage filter to the intake fuel manifold on the head.
This filter also is of the replaceable element type.
(2) Removal.
WRENCH, open-end, ys-in. WRENCH, socket, s/s-in.
WRENCH, socket, %e-in.
101
TM 9-787A
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HEAVY TRACTOR Ml
COVER
FILTER
ELEMENT
HOLD-DOWN
SCREW AND
CLAMP
GASKET
FITTINGS
i:^
DRAIN ^ »^
COCK '*^'
3 W
(J w ~=
ELEMENT
FILTER
GUIDE
FILTER _
HOUSING
MOUNTING
BANDS
RA PD 53978
Figure 53— Second Stage Filter Assembly— Exploded View
102
TM 9-787A
68
FUEL AND AIR SYSTEM
CAPSCREW
WASHER
GASKET
FILTER
HEAD
^'***"' upiiiiajiiiu— ""^
FILTER
ELEMENT
FILTER
HOUSING
GASKET
SPRING
DRAIN
COCK "A PD 53979
figure 54— Third Stage Filter Assembly —Exploded View
103
TM 9-787A
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HEAVY TRACTOR Ml
(a) Disconnect Fuel Lines.
WRENCH, open-end, '/s-in.
Disconnect the fuel lines from the fittings on filter head.
(b) Drain Fuel from Filter. Drain filter by opening drain cock at
bottom of filter.
(c) Remove Filter Housing.
WRENCH, socket, Vs-in.
Remove retaining cap screw holding filter housing to filter head and
remove filter housing.
(d) Remove Filter Head.
WRENCH, socket, 'Kfi-in.
Remove two cap screws holding filter head to cylinder head and re-
move filter head.
(e) Remove Element. Lift element and spring from filter housing.
»,-X^r
RA PO 17637
Figure 55— Removing Third Stage filter Housing
104
TM
9-787A
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FUEL AND AIR SYSTEM
RA PD 17607
Figure 56— Removing Third Stage Filter Head
(3) Maintenance. Clean filter housing with clean fuel oil after re-
moving the element. The element may be replaced without removing
the filter assembly from tractor. Remove the retaining screw and housing
will drop down and out (fig. 55). Use new gasket supplied with each new
element. Fill housing with fuel oil before installing housing on filter head.
Open drain cock daily to drain sediment and water from filter.
(4) Installation.
WRENCH, open-end, ys-in. WRENCH, socket, s/a-in.
WRENCH, socket, %6-in.
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(a) Install Filter Head.
WRENCH, socket, % g-in-
Install filter head to cylinder head with two cap screws.
(b) Install Element in Housing. Install the spring and new element
in the housing with the end marked "TOP" up, and fill the housing with
fuel. NOTE: Two interchangeable types of filter cartridges are supplied
for use in the third stage fuel filter. One is a cotton-wound type similar
to the filter elements used in the filters located under the seat. A steel
washer is supplied with each of these cartridges, and when this type
filter element is used, the washer should be placed on the hollow stud
inside the filter housing before the gasket and filter are installed.
(c) Install Housing.
WRENCH, socket, Ys-in.
Install new gaskets in filter head and on top of element; install cap
screw and draw housing up to head (fig. 55).
(d) Connect Fuel Lines.
WRENCH, open-end, yg-in.
(e) Check for Leaks. Start engine and check for leaks.
69. FUEL PUMP.
a. Description. The fuel pump is a positive displacement, vane-
type pump. It is bolted to the rear end cover of the blower and is driven
by the lower blower rotor shaft. A U-shaped steel stamping forms a part
of the drive assembly and provides a safety release if the pump should
lock for any cause.
b. Removal.
WRENCH, box, o/ie-in. WRENCH, special fuel pump
WRENCH, open-end, '/s-in.
( 1 ) Close Fuel Shut-Off.
(2) Disconnect Fuel Lines from Pump.
WRENCH, open end, Vs in.
Disconnect inlet and outlet lines from pump.
(3) Remove Fuel Pump FROM Blower.
WRENCH, box, ^g-in. WRENCH, fuel pump
Remove the three cap screws holding fuel pump to blower. Use the
special wrench to remove the cap screw nearest the cylinder block. Re-
move the fuel pump assembly and drive coupling fork as a unit.
c. Maintenance. No maintenance will be attempted by the using
arm personnel.
d. Installation.
WRENCH, box, y2-in. WRENCH, special fuel pump
WRENCH, open-end, ys-in.
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RA PD 17611
Figure 57 —Disconnecting fuel Lines from Fuel Pump
( 1 ) Install Coupling Fork on Pump. Put drive coupling fork (arms
out) on the square outer end of the pump shaft. Use a new paper gasket
on the pump support flange.
(2) Install Pump.
WRENCH, box, Va-in. WRENCH, special fuel pump
Install pump assembly on the blower end housing, engaging the drive
fork in the slots of the driving plate on the lower blower rotor shaft.
NOTE : The "IN" marking on the pump body should be on the cylinder
block side, and the fuel line from the fuel supply tank connected to the
fitting on the "IN" side of the pump body.
(3) Connect Fuel Lines to Pump.
WRENCH, open-end, '/g-in.
(4) Open Fuel Shut-Off Valve.
(5) Test for Operation. Start engine and check for leaks and fuel
pressure.
70. INJECTORS.
a. General. To secure combustion, a small quantity of accurately
metered, finely atomized fuel must be mixed, near end of the compres-
sion stroke, with the charge of air which has been forced into the cylinder
107
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RA PD 17613
Figure 58— Removing Cap Screws from Pump with Special Wrench
by the blower. This is accomplished by an injector, which is a high
pressure fuel injection device. There is one injector for each cylinder.
The injectors in this 2-cycle engine are called unit injectors because
they are a combination injection pump and injection nozzle or valve. The
function of an injection pump is threefold: to meter out the exact amount
of fuel to be supplied to each cylinder, to put that fuel under a pressure
high enough to assure proper atomization or breaking up of the fuel for
rapid ignition when it is released into the highly heated air of the
cylinder, and to time its injection at exactly the right point in the oper-
ating cycle. The function of an injection valve is to insure that fuel is
not admitted to the cylinder until it is at a high enough pressure to
atomize properly for quick ignition, and that injection stops as soon as
the pressiire drops below the lowest permissible injection pressure. These
functions are combined in the unit injector for each cylinder of this
engine. For convenience, this combined pump and injector unit is here
referred to as the injector.
b. The injectors are mounted in the cylinder head with their spray
tips projecting slightly below the head into the combustion chambers. A
clamp, bolted to the cylinder head, holds the injector in place in a water-
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I
RA PD 17616
Figure 59— Removing Fuel Pump
cooled copper tube in the head. A dowel pin in the injector body registers
with a hole in the cylinder head for accurately locating the injector
assembly. A taper seat on the lower end of the injector, when seated in
the copper tube in the cylinder head, forms a seal against the pressure of
the compression in the cylinder.
c. Operation. Each injector is operated by a push rod and rocker
arm in the same manner as the exhaust valves. As the piston nears the
top of its compression stroke, the rocker arm forces the injector plunger
down. The fuel is forced, by the plunger, into the combustion chamber
through six holes in the injector spray tip. These holes, only 0.006 inch
in diameter, distribute the fuel and break it into a very fine spray. A
faulty injector will usually result in a loss of power, uneven operation
of the engine, or a black exhaust smoke. Injectors can be "cut out" in
much the same manner as shorting out spark plugs on a gasoline engine.
With hood and rocker arm cover removed and engine running at about
Ys throttle, "cut out" one injector at a time by pushing down on the
injector plunger follower with a stick of wood about V2 inch square.
NOTE: Damage may be done if a screwdriver is used. The one that
seems to have no effect on the operation of the engine when "cut out"
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FOLLOWER GUIDE -
RETURN SPRING -
HEAVY TRACTOR Ml
FOLLOWER
FILTER CAP
FILTER SPRING
GASKET
FILTER ASSEMBLY
BODY
CONTROL RACK
FUEL CAVITY
PLUNGER
SPHERICAL CHECK
VALVE SEAT ^
SPHERICAL CHECK VALVE
SPRAY TIP
SPILL DEFLECTOR
LOWER HELIX
LOWER PORT
FLAT CHECK VALVE
CHECK VALVE STOP.
CHECK VALVE SPRING
RAPD 17255
Figure 60— Cross Section of Injector
will be the faulty injector. It should be removed and a new or rebuilt
injector installed.
d. Removal.
TOOL, injector remover WRENCH, open-end, i%6-in.
WRENCH, open-end, yig-in. WRENCH, socket, %8-in.
WRENCH, open-end, Va-in. WRENCH, socket, 3/4-in.
( 1 ) Remove Precleaners
WRENCH, open-end, % s -»«•
Loosen clamps holding precleaners to stacks and remove precleaners.
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PRE-CLEANER
EXTENSION TUBE
RA PD Sfr4l6
Figure 61— Removing Precleaners
(2) Remove Hood.
WRENCH, open-end, "/ifi-in.
Loosen the nuts on the hood hold-down straps at each corner of the
hood; pry bolts out of slot and remove the hood.
(3) Remove Rocker Arm Cover. Clean the rocker arm cover
thoroughly and remove the cover by loosening the two hand screws that
hold the rocker arm cover to the cylinder head.
(4) Remove Fuel Lines.
WRENCH, open-end, Va-in.
Disconnect the fuel lines of the injector to be removed and place
shipping caps on the fuel fittings to prevent dirt from entering the fuel
system (fig. 33).
(5) Remove Rocker Shaft Brackets.
WRENCH, socket, 2/4 -in.
With a %-inch socket wrench, remove the two special cap screws that
hold the rocker arm assembly to the head and slide the brackets off
the rocker arm shaft (fig. 34).
Ill
TM 9-787A
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RA PD 17714
Figure 62— Removing Hood Clamp
(6) Remove Rocker Arm Shaft. Slide shaft from the rocker arms
before laying the assembly back out of the way. This should be done to
avoid bending the push rods.
(7) Remove Injector Clamp.
WRENCH, socket, %6-in.
Remove the nut holding clamp and lift off clamp washer and injector
clamp.
(8) Remove Injector.
TOOL, injector remover
Place square end of injector tool under shoulder of injector body and
pry injector from its seat; at "the same time disengage the control rack
linkage.
e. Testing Fuel Injectors (fig. 60). An injector should always be
tested before it is installed in the engine. This test, known as "popping
the injector," is accomplished as follows:
(1) Place injector in test fixture.
(2) Using a clean oil can filled with clean fuel oil, introduce fuel
into one of the injector openings until fuel flows from the other opening.
(3) To determine whether all six holes in the spray tip are open,
move the injector rack into the "FULL FUEL" position; then forcibly
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4a«34 >
Figure 63— Removing /n/ector Clamp Nut
RAPD 40(135 1
Figure 64— Lifting Out Injector Clamp
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TM 9-787A
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press the test handle down on the plunger follower with a quick motion.
When the check valve opening pressure is correct, considerable down-
ward pressure will be required on the fixture handle to pop the injector;
if but little pressure is required, the check valve opening pressure is too
low. CAUTION: Keep hands away from the spray tip when popping
the injector, as the fuel from the spray tip will penetrate the skin and
may cause blood poisoning. It is advisable to use a shield around the
spray tip.
(4) Test for a leaky check valve by wiping or blowing all fuel from the
spray tip, then pressing down on the fixture handle firmly, but not
forcibly enough to open the check valve. Maintain a steady pressure
while watching the spray tip. If oil appears, the check valve is not
seating properly.
(5) If the injector fails to pass these tests, notify ordnance main-
tenance personnel. NOTE: Never remove the filter from the injector
because of the risk of getting dirt into the oil passages.
f. Installation.
WRENCH, open-end, 1/2-in. WRENCH, socket, 3/4 -in.
WRENCH, socket, %6-in.
(1) Place the Injector in the Injector Tube. A dowel, pro-
vided on the injector body, registers with a hole in the cylinder head
Figure 65— Injector Removal
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Figure 66— Injector Removed
so that the injector Can be located in only one position in the head.
Engage the control rack with the control lever at the same time.
(2) Install the Injector Clamp.
WRENCH, socket, ^e-in.
Place clamp on the injector body, centering the side arms of the
clamp as well as possible in the machined recesses in the injector body.
Drop the special washer over the stud, with rounded side down. Put
nut on stud and draw down clamp firmly, using wrench with 8-inch
handle (fig. 63).
(3) Install Rocker Arm Shaft and Brackets. Slide shaft
through rocker arms and place a bracket on each end of shaft, with
the smooth side of brackets towards rocker arms.
(4) Install Cap Screws.
WRENCH, socket, y4-in.
Draw brackets down firmly, at the same time holding rocker brackets
loosely against rocker arms, allowing from 0.003-inch to 0.006-inch
clearance.
(5) Connect Fuel Lines.
WRENCH, open-end, Va-in.
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Remove the shipping caps from fuel fittings in head and on injectors,
and connect fuel lines. After engine ha? been started, check for leaks
before installing rocker arm cover. NOTE: The injector must be
timed and equalized and the valve clearance adjusted (par. 60) before
the rocker arm cover, hood, and precleaners are installed.
g. Injector Timing (fig. 67). The timing of an injector consists of
properly locating the top of the injector plunger follower in relation
to the injector body when it is at the top of its stroke. This distance
is 1.484 inches and a special tool called a timing gage (in the injector
service kit) is used to make the proper adjustTnent. After installation
of an injector, or if the rocker arm assembly has been worked upon,
the injector must always be timed and equalized before the engine is
operated. The following procedure should be used to time the injectors.
(1) Pull Fuel Shut-Off to "OFF" Position.
GAGE, timing WRENCH, open-end, %6-in-
SCREWDRIVER, small WRENCH, open-end, Vi-in.
Do not allow the engine to start. Crank engine with the starting motor
until the exhaust valves of the cylinder on which the injector is to be
timed are fully opened. When the rocker arms have depressed the
exhaust valves, the injector may be timed.
(2) Set Timing Gage in Position.
GAGE, timing SCREWDRIVER, small
Place the timing gage in the timing hole in the injector body. The
knurled head or sleeve should be turned to the left as far as possible.
Hold the gage vertical with a firm downward pressure with a small
screwdriver engaged in the slot in the top of the timing gage shaft.
Make certain that the shoulder at the lower end of the timing gage
shaft rests squarely on the injector body and is not resting on the
copper gasket under the fuel line fitting in the injector.
KNURLED SLEEVE-
1.484
SHAFT-
RA PD 53980
Figure 67— Injector Timing Gage
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RA PD 56386
Figure 68— Injector Timing
(3) Check Present Setting.
GAGE, timing
Rotate the knurled sleeve to the right until the lower shoulder of
the sleeve rests squarely on the edge of the follower guide. If the top
of the shaft and the sleeve are not flush and the marks "C" on the
sleeve and shaft are not in line, the push rod must be lengthened or
shortened to obtain the proper adjustment.
(4) Adjust Push Rod.
WRENCH, open-end, y4-in. WRENCH, open-end, Vi-in.
Loosen the lock nut on the push rod. Adjust the rocker arm by
turning the push rod to the right to shorten it, which will allow the
injector plunger follower to come up. Turning the push rod to the left
will lengthen the push rod and will push the plunger follower guide
down. When the timing marks line up, with' a small allowance for a
slight change which occurs when the lock nut is tightened, the sleeve
should also be flush with the top of the timing shaft. Tighten the lock
nut on the push rod. The timing marks should now be exactly in line, i
If they are not in line, change the adjustment slightly until the marks
line up when the lock nut is tight.
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PLUNGER FOLLOWER
TIMING GAGE
LOCK NUT
PUSH ROD
RA PD 56387
Figure 69— Correct Timing of Injector
h. Injector Equalizing. This operation consists of properly adjust-
ing all injector control racks to obtain an equal fuel injection from each
injector. Accurate timing of the injectors is essential before they are
equalized. The injector must be timed and equalized every time any
part of the engine is worked on which might affect the position of the
injector or rocker arm assembly. Equalizing is accomplished by the
following procedure.
(1) Push Fuel Shut-Off Forward (Open).
PLIERS SCREWDRIVER
Push fuel shut-off all the way forward and pull throttle back (open)
as far as possible.
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(2) Loosen Adjusting Screws.
SCREWDRIVER
Loosen all adjusting screws on the rack control levers and be sure
the levers are free on the control tube and that the control tube rotates
freely in the bearings.
(3) Disconnect Governor Control Link.
PLIERS
Remove link pin from governor control link and control tube lever.
All injector control racks should move freely and the injector control
tube assembly should return to the "NO INJECTION" position (in-
jector rack out) when the governor control link^is disconnected.
(4) Adjust for Control Rack and Gear Clearance.
SCREWDRIVER
Hold the throttle lever on the top of the governor in full load position
and turn the lower adjusting screw for No. 1 injector in until the hole
for the pin in the control tube lever is %4 of an inch out of line with
the hole in the governor control link (fig. 70). Turn the upper adjusting
screw down and tighten both screws lightly so the % 4 -inch spacing is
maintained.
RA PD 17664
figure 70— No. I Control Rack Adjustment
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GOVERNOR CONTROL
LINK
INJECTOR RACK
CONTROL LEVER
INJECTOR CONTROL RACK
Figure 71— Clearance for Control Rack and Gear
(5) Adjust Remaining Rack Control Levers. Hold No. 1 rack
control lever against No. 1 injector control rack in its "IN" position
and adjust the remaining rack control levers until the lugs on all rack
control levers just contact the inner faces of the slots in the injector
control racks. CAUTION: The adjusting screws will be damaged if
drawn too tightly. If they are just screwed down firmly, they will not
loosen.
(6) Connect Governor Control Link. Install link pin in governor
control link and control tube lever, and secure with cotter pin. Install
rocker arm cover, start engine, and test for proper operation.
71. FUEL LINES AND CONNECTIONS.
a. The fuel lines and connections should be inspected regularly and
any damaged or defective parts removed for repair, or replaced with
new ones. The fuel lines are steel tubing, and it is important to avoid
bending them. All clips that hold the fuel lines to the tractor trans-
mission case and to the engine should be tight. Practically all the fuel
line connections have connector nuts requiring a ys-inch open-end
wrench. Any time a fuel connection is broken, the engine should be
started after the line is connected again and inspection made for leakage
of fuel or loss of fuel pressure due to air being drawn into the fuel sys-
tem through a defective or loose connection.
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FUEL AND AIR SYSTEM
h. It is important that the clips holding fuel lines to parts of the
tractor be installed again in the proper places when lines are replaced.
These clips prevent breakage of lines from vibration. Always use a
wrench, not pliers, when connecting or disconnecting fuel lines.
72. PRECLEANERS.
a. Description. The United precleaners, model C-11215, are of the
cyclone type. Approximately 85 percent of the dirt entering with the
air is removed by them before the air reaches the oil bath air cleaner.
Glass inspection ports make it easy for the operator to observe the quan-
tity of dirt and dust in the dirt compartment and enables him to readily
determine when it should be emptied from the precleaners. If pre-
cleaners become damaged, they should be immediately replaced.
b. Removal.
WRENCH, open-end, 'Atr^n. (2)
(1) Loosen Clamp.
WRENCH, open-end, "^^-in. (2)
Loosen clamp bolt at base of precleaner and lift ofif precleaner assem-
bly (fig. 61).
c. Maintenance. The precleaners should be emptied daily, or oftener
if necessary. In any case, they should be emptied before dirt is level
with top of glass.
( 1 ) Remove wing nut assembly from the top of precleaners and
remove bowl.
(2) Shake dust from dirt compartment.
(3) Wipe glass and reassemble. Replace rubber gasket if present
one is not in good condition.
(4) Tighten wing nut with fingers. CAUTION: Do not use a wrench.
d. Installation.
WRENCH, open-end, Vui-'m. (2)
(1) Place Precleaner Assembly on Pipe.
WRENCH, open-end, "/i,.,-in. (2)
Place precleaner assembly in position over pipe, pushing it down as
far as possible, and tighten clamp bolt.
73. AIR CLEANER,
a. Description. A United oil bath air cleaner, model CT 85 9665, is
used on this tractor and is mounted under the tractor cowl. It consists
of two air cleaner assemblies connected to one bracket. Oil cups with
bafHe plates are suspended at the lower end of the air cleaner assemblies
and are filled to a specified level with engine oil. As the air is drawn
through the cleaners, a portion of this oil is whipped up into screen
121
TM 9-787A
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HEAVY TRACTOR Ml
mats in the main body of the cleaners. The dust in the air collects on
these oily screen mats as the air is drawn through them and, as a result,
only clean air reaches the engine. The oil dripping back into the cups
from the screen mats carries the dirt with it and deposits it in the cups.
The cups must be removed periodically and cleaned to remove this
dirt. A broken hose, loose clamps, or a leak of any kind between the air
cleaners and the blower will defeat the purpose of the cleaner; there-
fore, care should be taken to see that all connections are tight.
b. Maintenance. The cleaners must be checked every 8 hours of
operation. Remove the oil cups and check the amount and condition
of the filtering oil. In extremely dusty conditions, the oil should be
changed every 8 to 10 hours and the air inlet pipe in the air cleaner
swabbed out to remove any dust accumulation on the sides of the
passage. Improper care of the air cleaners will result in abnormal wear
on blower, rings, pistons, and cylinder liners. The air cleaner should
be serviced as follows:
( 1 ) Swing bail assembly from under cup and remove cup.
(2) Remove baffle ring and baffle.
(3) Empty oil and dirt and thoroughly clean cup, baffle, and baffle
ring.
AIR CLEANER
AIR CLEANER CUP
RA PD 17621
Figure 72 — Removing Air Cleaner Cup
122
TM
9-787A
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FUEL AND AIR SYSTEM
RA PD 17660
Figure 73 — Removing Baffle and Baffie Ring
(4) Replace baffle and baffle ring, and fill cup to the oil level line
at top of cone with OIL, engine, SAE 30. (See section IV for proper
seasonal grade). CAUTION: Do not use a Diesel engine oil in the air
cleaner as oils of this type are likely to foam and reduce the efficiency
of the air cleaner.
(5) Replace cup on cleaner assembly and snap bail assembly into
place under the cup.
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HEAVY TRACTOR Ml
Section XIII
COOLING SYSTEM
Paragraph
Description 74
Water pump^ 75
Water manifold 76
Radiator 77
Thermostat '. . 78
Hoses and pipes 79
Fan assembly 80
74. DESCRIPIION.
a. Cooling of the engine is accomplished by means of water circu-
lated through the cylinder block and cylinder head by a centrifugal
pump mounted on the front end of the blower and driven by the lower
blower rotor shaft. This pump delivers the heated water to the top of
the radiator core. A cooling fan is provided which draws air through
the radiator core, thus dissipating the heat and lowering the water tem-
perature while it passes from the- top to the bottom of the radiator.
b. Keep cooling system filled with clean water that is free from
lime or other alkalies. Use a standard antifreeze solution in the cooling
system in winter weather. The solution should be tested daily and kept
at the proper strength for prevailing temperatures. The antifreeze used
should have a higher boiling point than the normal operating tempera-
ture of the engine (160 to 180 F).
c. The cooling system has two drain points (fig. 24) and both of
these should be opened when the cooling system is drained or the unit
is stored. One drain cock is in the bottom of the water pump housing
and the other is in the bottom of the elbow connecting the radiator to
the lubricating oil cooler assembly. CAUTION: When refilling cooling
system, remove the V4-inch pipe plug in the thermostat housing. This
will permit air to escape from the head and block. As soon as water
runs out of the hole freely, the plug should be replaced and the system
filled to its specified capacity, 9% gallons.
75. WATER PUMP.
a. Description. The water pump is mounted on the forward end of
the' blower housing (fig. 76). It is driven by the lower blower rotor shaft
through a jaw type coupling. This coupling fits on the shaft with a light
press fit. If the pump becomes frozen or otherwise bound, the coupling
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TM 9-787A
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COOLING SYSTEM
will turn on the shaft and will thus prevent damage to the pump itself.
If this happens the pump must be removed and repaired or replaced, and
the coupling must be replaced.
b. Trouble Shooting.
(1) Overheating.
Probable Cause
Pump drive shaft coupling turning
on shaft.
Impeller turning on shaft.
(2) Noisy Pump.
Bearing defective.
Impeller defective.
(3) Loss OF Water.
Water pump seal faulty.
c. Removal.
SCREWDRIVER
TOOL, water pump drain
WRENCH, open-end, Va-in.
WRENCH, open-end, %6-in.
WRENCH, open-end, s/s-in.
Probable Remedy
Replace coupling.
Replace pump.
Replace pump.
Replace pump.
Replace pump.
WRENCH, open-end, y4-in.
WRENCH, socket, 3/4 -in.
WRENCH, water pump and
fuel pump
(1) Drain Cooling System.
TOOL, water pump drain
Open both water pump and radiator drain cocks. If antifreeze solution
is in cooling system, drain into clean containers to save for refilling
radiator.
(2 ) Remove Right Front Fender.
WRENCH, open-end, %-in. WRENCH, socket, y4-in.
Remove three bolts and one cap screw holding fender and remove
fender.
(3) Remove Governor Breather Tube.
SCREWDRIVER
Remove two screws holding top of tube to gpvernor housing and lift
tube out of clip on oil cooler housing.
(4) Disconnect Air Compressor Water Inlet Line.
WRENCH, open-end, Vs-in. WRENCH, socket, %e-in.
Remove cap screw from clip holding tube against balance weight
cover. Disconnect water line from pump.
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RA PD 17S07
Figure 74— Removing front Fender
(5) Disconnect Hose.
SCREWDRIVER
Loosen hose clamp on hose connection between water pump and oil
. cooler.
(6) Disconnect Pump Outlet Packing Flange.
WRENCH, open-end, Va-in.
Remove the two cap screws holding pump outlet packing flange to
cylinder block.
(7) Remove Pump Assembly.
WRENCH, water pump and fuel pump
Remove the three cap screws holding water pump to front end of
blower and remove pump assembly and coupling.
d. Installation.
SCREWDRIVER
TOOL, water pump drain
WRENCH, open-end, Va-in.
WRENCH, open-end, %6-in-
WRENCH, open-end, %-in.
WRENCH, open-end, 3/4 -in.
WRENCH, socket, 3/4 -in.
WRENCH, water pump and
fuel pump
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RA PD 17618
Figure 75— Removing Cap Screws from Pacldng Flange
(1) Install New Coupling on Pump Shaft. Place coupling on
pump shaft with jaws pointing towards blower. See that packing flange
and packing ring are in posijtion on the discharge pipe and that the
hose connection from the pump to the oil cooler is in place. Use new
gasket, if necessary.
(2) Install Pump Assembly.
WRENCH, water pump and
fuel pump
Install the pump assembly on the front end cover of the blower with
three cap screws taking care that the driving jaws of the coupling engage
the driving assembly on the blower rotor shaft.
(3) Tighten All Hose Connections.
(4) Connect Air Compressor Water Inlet Line.
SCREWDRIVER WRENCH, socket, %6-in.
WRENCH, open-end, %-in.
Connect water inlet line to pump and install cap screw through pipe
clip and into balance weight cover.
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HEAVY TRACTOR Ml
RA PD 17617
Figure 76— Removing Water Pump
(5) Connect Pump Outlet Packing Flange.
WRENCH, open-end, 1/2-in.
(6) Install Breather Tube.
SCREWDRIVER
Insert lower end of tube through clip on oil cooler and install screws
holding tube to governor housing.
(7) Fill Cooling System.
TOOL, water pump drain
Close drain cocks; fill cooling system; start engine and check for leaks.
NOTE: As the water pump ball bearing is the "shielded" type and
filled with lubricant when assembled, no further lubrication is necessary.
76. WATER MANIFOLD.
a. Description. The water manifold is bolted to the left side of the
cylinder head and discharges the cooling water back into the radiator.
The thermostat is located in a special housing bolted to the front end
of the manifold and its purpose is to restrict the flow of cooling water
to automatically maintain the correct temperature for proper engine
operation.
128
TM 9-787A
76
COOLING SYSTEM
WRENCH, open-end, s/s-in.
WRENCH, open-end, n/io-in.
b. Water Manifold Removal.
SCREWDRIVER
WRENCH, open-end, 1/2-in.
WRENCH, open-end, %6-in.
( 1 ) Drain Cooling System.
(2) Disconnect Hose FROM Thermostat Housing.
SCREWDRIVER
(3) Remove Thermostat Housing.
WRENCH, socket, Va-in.
Remove three cap screws from thermostat housing and disconnect
water bypass tube from thermostat (fig. 78).
(4) Remove Water Line.
WRENCH, open-end, %-in.
Remove water Hne leading to the air compressor.
(5) Remove Thermo Gage Tube.
WRENCH, open-end, n/ie-in.
Remove tube of thermo gage from rear of manifold.
(6) Remove Manifold.
WRENCH, open-end, %6-in.
Remove the eight nuts and lock washers from stud Jbolts holding
manifold to head and lift off manifold.
RA PD 17631
Figure 77— Removing Water Manifold
129
TM 9-787A
76-77
HEAVY TRACTOR Ml
c. Installation.
GREASE, chassis WRENCH, open-end, %6-in.
SCREWDRIVER WRENCH, open-end, s/s-in.
SHELLAC WRENCH, open-end, n/is-in.
WRENCH,, open-end, Va-in.
(1) Install Gaskets on Manifold. Scrape all old gaskets off
head and manifold, and shellac new gaskets to manifold. Coat other
side of gaskets with chassis grease.
(2) Install Manifold ON Head.
WRENCH, open-end, %B-in.
Place the manifold on the head and tighten all the nuts evenly.
(3) Install Thermo Gage Tube.
WRENCH, open-end, n/ie-in.
Install the thermo gage and tube in the rear end of the manifold.
(4) Install Thermostat and Housing.
WRENCH, open-end, 1/2 -in.
Install the thermostat and housing and connect the water bypass tube
to the thermostat housing (fig. 79).
(5) Install Water Line.
WRENCH, open-end, Vs-in.
Install water line leading to air compressor.
(6) Fill Cooling System. Fill the cooling system, start the engine
and inspect for leaks.
77. RADIATOR.
a. Description. After the engine has reached operating temperature,
the thermostat opens and allows the water to circulate through the
radiator. The fan draws air through the radiator core and cools the hot
water coming from the engine. The radiator core is bolted inside a shell
and protected by the grill in front.
b. Trouble Shooting.
(1) Overheating.
Probable Cause Probable Remedy
Lack of water. Fill radiator.
Radiator clogged. Clean and flush.
Dirt, trash, or insects in radiator Blow out with compressed air.
air passages.
Rotted hoses. Replace hoses.
130
TM 9-787A
COOLING SYSTEM
(2) Loss OF Water.
Probable Cause Probable Remedy
Leaks in radiator core. Notify ordnance personnel.
Radiator clogged so that water Clean and flush.
builds up in top tank and is lost
through overflow.
c. Maintenance. The cooling system should be flushed out periodi-
cally to remove accumulated loose rust or foreign material. This may
be done with clean water or with SOLVENT, dry-cleaning, which is not
injurious to steel, cast iron, or copper. Follow directions for flushing as
given below.
(1) For flushing with clean water proceed as follows:
(a) Drain the cooling system and disconnect the water bypass tube
at the thermostat housing (fig. 78).
(h) Remove the thermostat (par. 78).
(c) After the thermostat has been removed, bolt housing back to the
water manifold, and reconnect the water bj^pass tube.
(d) System may now be flushed. Fill the cooling system; start the
engine; then open both drain cocks and, using a hose, keep the radiator
filled as the water runs through the system and drains out.
(e) When all the rust, etc., has been flushed from the system, stop the
engine; install the thermostat; close the drains; and refill the system.
(2) If SOLVENT, dry-cleaning, is used to clean the cooling system,
a different procedure should be followed:
(a) Drain the cooling system.
(h) Close the drains and fill the system with cleaning solution.
(c) Start the engine and run it for about an hour, regulating the
radiator shutter to hold the engine temperature at 190 F.
(d) Drain the solution; flush radiator thoroughly, and refill.
(3) If trash or foreign material has gathered at the top of the tubes
in the radiator core, back flushing of the radiator is necessary.
(a) Drain the cooling system and remove radiator cap.
(h) Disconnect the hose from the elbow in which the main drain
cock is located.
(c) Insert a water hose inside this hose, and stuff a cloth around it
if an adapter is not available for connection.
(d) Let water run slowly into radiator through hose until water runs
out the top of radiator, then increase the water pressure.
(e) Run water through the radiator in this way long enough to force
the obstructions off the top of the tubes and out the radiator filler pipe.
(t) Reconnect the lower hose and refill the cooling system.
131
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78
78.
HEAVY TRACTOR Ml
THERMOSTAT.
a. Description. The thermostat is located at the front end of the
water manifold and is designed to keep the operating temperature of the
cooling fluid at 170 F. There is a Vi-inch pipe plug in the thermostat
housing which must be removed whenever the cooling system is being
refilled in order to prevent air locks in the cylinder head and block.
b. Trouble Shooting.
(1) Engine Overheating.
Probable Cause
Thermostat not opening.
Probable Remedy
Replace thermostat.
(2) Engine Temperature Too Low.
Thermostat defective and remain-
ing open.
Thermostat gasket defective.
c. Removal.
SCREWDRIVER
WRENCH, open-end, 1/2 -in.
( 1 ) Drain Cooling System.
Replace thermostat.
Install new gasket.
WRENCH, socket, 1/2 -in., with
6-in. extension
RA PD 17634
Figure 78— Removing Thermostat Assembly
132
TM 9-787A
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COOLING SYSTEM
(2) Disconnect Radiator Hose.
SCREWDRIVER
Loosen clamp on hose connection.
(3) Disconnect Bypass Tube.
WRENCH, socket, V^-in., with 6-in. extension
Remove two cap screws holding the bypass tube to the thermostat
housing.
(4) Remove Thermostat Housing.
WRENCH, socket, Vz-in., with 6-in. extension
Remove the three cap screws holding the housing to the water
manifold.
(5) Remove Thermostat. Thermostat can now be slipped out of
the thermostat housing.
WRENCH, socket, Vi-in., with
6-in. extension
d. Installation.
SCREWDRIVER
SHELLAC
WRENCH, open-end, Va-in.
(1) Place Gasket Over Thermostat.
(2) Install Thermostat. Place thermostat in housing taking care
to keep gasket in place.
Figure 79— Installing Thermostat Assembly
133
RA PD 17635
TM 9-787A
78-80
HEAVY TRACTOR Ml
(3) Install Gasket on Housing.
SHELLAC
Shellac new gasket to thermostat housing and coat other side of gasket
with chassis grease.
(4) Install Assembly to Head.
WRENCH, socket, Va-in., with 6-in. extension
Hold assembly in place against head and tighten cap screws.
(5) Connect Radiator Hose.
SCREWDRIVER
Shellac inside of hose, tighten clamp.
(6) Connect Water Bypass Tube to Thermostat Housing.
WRENCH, socket, Va-in., with 6-in. extension
79. HOSES AND PIPES.
a. All hoses and connections should be inspected at regular intervals
to see that hoses are in good condition and that all connections are tight.
b. If it becomes necessary to replace a hose the clamps should be
loosened, hose removed, all connections shellacked, new hose installed,
and clamps replaced and tightened.
80. FAN ASSEMBLY.
a. Description. The fan assembly is mounted on a bracket fastened
to the balance weight housing on the front of the engine. The fan is
driven by two V-belts from a pulley on the crankshaft. The six-blade
fan is fastened to the pulley hub with four cap screws. Grease fitting is
furnished in fan hub to lubricate bearings (sec. IV).
b. Trouble Shooting.
(1) Engine Overheating.
Probable Cause Probable Remedy
Drive belts loose. Adjust to IVi-in. slack.
Drive belts broken. Replace belts.
(2) Fan Noisy.
Bearing defective. Replace fan assembly.
Fan loose on hub. Tighten fan assembly.
Blades bent. Replace fan blade assembly.
c. Removal.
WRENCH, fan, 1-in. WRENCH, socket, Vz-in.
WRENCH, open-end, 3/4 -in. WRENCH, socket, y4-in.
134
COOLING SYSTEM
TM 9-787A
80
RA PD 17711
Figure 80— Removing Fan Blade Assembly
( 1 ) Remove Fan Blade Assembly.
WRENCH, socket, Va-in.
Remove fan blade assembly by removing four cap screws holding it
to pulley.
(2) Remove Adjusting Sckew.
WRENCH, open-end, 3/4-in.
Loosen lock nut and turn adjusting screw from spindle and bracket.
(3) Remove Pulley.
WRENCH, fan, 1-in.
Remove pulley by removing jam nut and washer from fan spindle.
(4) Remove Bracket.
WRENCH, socket, 3/4-in.
Remove three cap screws and lock washers holding bracket to engine
and remove bracket. NOTE: Fan blade assembly pulley, shaft, and
, bracket may be removed as a unit by performing this last step.
135
TM 9-787A
80
HEAVY TRACTOR Ml
Figure 81— Removing fan Assembly
d. Installation.
WRENCH, fan, 1-in.
, WRENCH, open-end, 3/4-in.
WRENCH, socket, Va-in.
WRENCH, socket, 3/4-in.
(1) Install Bracket. Install bracket to engine with the three cap
screws and lock washers.
(2) Install Pulley. Insert fan spindle through opening in bracket,
place washer on fan spindle and start nut.
(3) Install Adjusting Screw.
WRENCH, open-end, y4-in.
With jam nut on screw insert screw through bracket and fan spindle.
(4) Install Belts and Fan Blade Assembly.
WRENCH, socket, Vi-in.
Place belts in grooves of pulley. Then bolt fan blade assembly to pul-
ley. Belts should now be adjusted.
136
TM 9-787A
80
COOLING SYSTEM
ADJUSTING SCREW
JAM NUT
JAM NUT
RA PD 56388
Figure 82— Fan Belt Adjustment
137
TM 9-787A
80
HEAVY TRACTOR Ml
e. Fan Belt Adjustment.
WRENCH, fan, 1-in. WRENCH, open-end, y4-in.
With jam nuts on adjusting screw and fan spindle loosened, turn
adjusting screw clockwise to tighten belts. Belts are correctly adjusted
when one side can be pressed towards the other side about IVi inch at
point halfway between the pulleys. Tighten adjusting screw jam nut, and
fan spindle jam nut.
f. Fan Belt Removal.
WRENCH, fan, 1-in. WRENCH, open-end, y4-in.
( 1 ) Loosen Jam Nut on Fan Spindle.
WRENCH, fan, 1-in.
Loosen the large nut in back of bracket on end of fan spindle.
(2) Loosen Fan Belts.
WRENCH, open-end, y4-in.
Loosen jam nut on adjusting screw and tiirn screw counterclockwise
to loosen belts enough to remove them from belt pulley grooves.
(3) Remove Belts. Remove one belt at a time. After removing belt
from fan pulley, remove belt from lower crankshaft pulley and work
belt off, over fan. Remove second belt in same manner.
g. Installation.
WRENCH, fan, 1-in. WRENCH, open-end, y4-in.
( 1 ) Install Belts. Work belts over fan. Place first belt in rear groove
of lower crankshaft pulley first, then work belt onto fan pulley into rear
groove. It may be necessary to turn fan by turning motor with engine
cranking wrench to run belt onto fan pulley. Install second belt in front
pulley grooves in same manner.
(2) Adjust Belts.
WRENCH, open-end, 3/4-in.
Adjust belts as described under paragraph 80 e.
138
TM 9-787A
81-82
Section XiV
LUBRICATION SYSTEM
Paragraph
General . 81
Oil pump 82
Oil filter 83
Oil cooler 84
81. GENERAL.
a. The lubrication system for the engine consists of the oil pump,
oil filter, and oil cooler. The engine block and head contain drilled
passages to deliver oil, under pressure, to most of the moving parts of
engine after passing through filter and cooler. The oil in returning to
the sump flows through other parts and bearings to lubricate them.
For proper lubricants and method of application see section IV.
82. OIL PUMP.
a. Description. The oil pump is a conventional gear type pump
mounted to one of the engine main bearing caps and driven by the
crankshaft through a chain and sprockets.
RA PD 17247
Figure 83— Lubricating OH Pump
139
TM 9-787A
82
HEAVY TRACTOR Ml
GASKET
OIL FILTER
HOUSING
OIL FILTER
ELEMENT
STUD
OIL FILTER AND
COOLER ADAPTOR ra pd 17260
Figure 84— Cutaway View of Lubricating Oil filter
140
TM 9-787A
82-83
LUBRICATION SYSTEM
b. Maintenance. No provision is made on the pump for increasing
or decreasing oil pressure. If pressure is not within normal range of
from 25 to 35 pounds at operating engine speed and temperature, stop
the engine immediately and report to higher authority. The using arm
will not attempt any maintenance on oil pump.
83. OIL FILTER.
a. Description. The oil filter, located on the front of engine, is of
the full flow type and consists of two metal elements inside a housing.
The bracket supporting the oil filter is cast with the adapter between
oil cooler and engine block.
b. A sudden drop in oil pressure would indicate that this filter is
plugged, possibly from sludge or dirt. Remove the filter and clean ele-
ments and base if this occurs.
c. Removal.
WRENCH, socket, 1 Vg-in.
( 1 ) Remove Filter Drain Plug.
WRENCH, square socket.
WRENCH, square socket,
V4-in.
.Remove plug at base of filter and allow oil to drain from filter.
Figure 85— Removing Lubricating Oil Filter
141
RAPD 17605
TM 9-787A
83
HEAVY TRACTOR Ml
(2) Remove Oil Filter Stud.
WRENCH, socket, IVs-in.
Remove stud and gasket and lift off filter housing and element.
1
RA PD 17601
Figure 86— Removing Lubricating Oil filter Hement
d. Maintenance. The metal element in the filter should be removed
and cleaned each time engine crankcase is drained and at any time
between oil changes that low oil pressure may be due to clogged filter.
(1) Wash the element in clean fuel oil with a soft brush. Do not
scrape with a sharp instrument or use a wire brush as damage may
result
(2) Wash all parts thoroughly, and dry them. Clean inside of filter
adapter. Make sure gasket in base of filter is in good condition when
filter is put back on tractor.
e. Installation.
WRENCH, socket, IVs-in. WRENCH, square socket,
y4-in.
(1) Examine Filter Housing Gasket. Make sure that this gasket
in base of filter is in good condition. If not, replace it.
(2) Set Elements in Place. Assemble screens, one inside the
other, and set them in adapter.
142
TM 9-787A
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LUBRICATION SYSTEM
(3) Install Housing AND Drain Plug.
WRENCH, socket, IVs-in. WRENCH, square socket, y4-in.
Place housing over elements, making sure that bottom of housing
enters groove in adapter. Install stud and gasket and tighten with 9-inch
handle for wrench. Install filter drain plug.
(4) Start Engine and Inspect for Leaks.
84. OIL COOLER.
a. Description. The oil cooler assembly consists of a housing inside
of which is a metal element somewhat similar to the core of a radiator.
Water from the radiator circulates around element in the cooler and
lubricating oil circulates through the element. The oil cooler plates are
lined with small fins which dissipate heat from the oil inside the element
to cooling water surrounding the element inside the cooler housing.
MPip«
RA PO 17261
figure 87— Oil Cooler Blement
h. If proper lubricating oil maintenance procedure is followed, the
cooler will function efficiently for an indefinite period. However, when oil
is allowed to become laden with impurities, these impurities will deposit
in the cooler; consequently causing clogging and inefficiency. To effec-
tively clean the cooler, it is necessary to remove cooler element and
circulate a special solvent through cooler element for some time by use
of a force pump.
c. RemovaL
SCREWDRIVER
WRENCH, open-end, 1/2 -in.
WRENCH, open-end, 3/4-in.
WRENCH, socket, %6-in. with
extension
( 1 ) Remove Right Front Fender.
WRENCH, open-end, 3/4-in.
Remove cap screw and bolts holding fender and remove fender.
143
WRENCH, socket, y4-in.
WRENCH, socket, IVs-in.
WRENCH, square socket, y4-in.
WRENCH, socket, y4-in.
TM 9-787A
84
HEAVY TRACTOR Ml
(2) Drain Cooling System and Oil Filter.
WRENCH, square socket, 1/4 -in.
Drain cooling system and drain oil from filter by removing drain plug
in adapter.
(3) Remove Oil Filter.
WRENCH, socket, IVs-in.
Remove filter housing and element by removing filter stud and gasket.
(4) DiscoNNEdT Water Bypass Tube.
WRENCH, socket, Va-in.
Remove cap screw holding water bypass tube clip to cooler housing.
(5) Remove Governor Breather Pipe Clip.
WRENCH, socket, %6-in.
Remove cap screw holding governor breather pipe clip to oil cooler.
(6) Remove Engine Support Bottom Cover.
WRENCH, socket, s/ie-in.
Remove cap screws holding cover to engine support and remove cover.
(7) Disconnect Hoses.
SCREWDRIVER
WRENCH, socket, Vz-in., with
short extension
RA PD 17626
Figure 88— Removing Engine Support Bottom Cover
144
TM 9-787A
84
LUBRICATION SYSTEM
Loosen clamp on hose connecting water pump and oil cooler. Slip hose
connection between water pump and cooler down onto cooler pipe.
Remove two cap screws from lower water connection.
(8) Remove Cooler Housing.
WRENCH, socket, % e-i"-, with
short extension
Remove the eight cap screws and lock washers holding cooler housing
to oil filter and cooler adapter and remove housing and element.
-FILTER STUD
- GASKET
* ^ FILTER
'\ ^Kk HOUSING
OIL cooler oil cooler drain
HOUSING ELEMENT PLUG
GASKET GASKET I 1
ADAPTER
GASKET
LOCKWASHER
CAP SCREW
RA PD 56389
Figure 89— Lubricating Oil Filter and Cooler Assembly
145
TM 9-787A
84
HEAVY TRACTOR Ml
d. Installation.
SCREWDRIVER WRENCH, socket, y4-in.
SHELLAC WRENCH, socket, IVs-in.
WRENCH, open-end, Va-in. WRENCH, square socket, Vi-in.
WRENCH, open-end, 3/4 -in.
WRENCH, socket, %6-in.,
with extension
( 1 ) Shellac Cooler Gaskets. Clean element housing and adapter
surfaces and shellac both sides of cooler gasket.
(2) Install Element and Housing.
WRENCH, socket, %fi-in., with extension
Place new element in housing and stick gasket to housing. Install
assembly to engine with cap screws and lock washers.
(3) Install Hoses.
SCREWDRIVER WRENCH, socket, Va-in., with
extension
Connect hose at inlet of cooler and tighten clamp. Install cap screws
in lower water connection and tighten, using a new gasket if necessary.
(4) Connect Water Bypass Tube.
WRENCH, open-end, Vz-in.
Shellac both sides of a new gasket and install gasket and water
bypass tube to cooler.
(5) Install Cap Screw Holding Governor Breather Pipe Clip.
WRENCH, socket, %6-in.
(6) Install Oil Filter and Plug.
WRENCH, socket, IVs-in. WRENCH, square socket,
y4-in.
Install filter and drain plug in adapter.
(7) Install Fender.
WRENCH, open-end, 3/4-in. WRENCH, socket, y4-in.
Install fender with cap screw, bolts and lock washers.
(8) Start Engine and Inspect for Leaks. Fill system with water,
start engine, and inspect all connections for leaks.
146
TM 9-787A
85-86
Section XV
ELECTRICAL SYSTEM AND EQUIPMENT
Paragraph
Description 85
Batteries 86
Generator 87
Generator voltage regulator , 88
Starting motor 89
Ammeter 90
Hour meter 91
Air heater 92
Light switch 93
Panel light 94
Service lights 95
Wiring , . . 96
85. DESCRIPTION.
a. A 12-volt electrical system is used on the tractor. Two 6-volt
batteries are connected in series. The capacity of the generator is suf-
ficient to keep the batteries fully charged under normal operating
conditions. CAUTION: Before working on any part of the electrical
system first disconnect the battery ground cable. Do not reconnect
the battery ground cable until all other equipment has been connected.
This will prevent shorts and damage to the electrical units.
86. BATTERIES.
a. Description. The batteries are located under the seat. The posi-
tive cable is grounded to the transmission. The batteries supplied with
the tractor are of two kinds and may be equipped with a "NO-OVER-
FLO" device. This is a lead washer in each vent well which is designed
to prevent overfilling.
b. Trouble Shooting.
(1) Discharged Battery.
ProbabI* Cauie Probable Remedy
Short circuits. Locate and correct shorts.
Connections loose. Tighten connections.
Connections dirty or corroded. Clean connections and coat ter-
minals with COMPOUND,
rust-preventive, light.
Voltage control unit out of order. Replace.
Generator not charging. Check generator and control xmit.
147
TM 9-787A
86
HEAVY TRACTOR Ml
(2) Battery Overheating.
Probable Cause Probable Remedy
Voltage control unit out of order. Replace.
High charging rate. Notify ordnance personnel.
c. Removal.
SCREWDRIVER
WRENCH, open-end, %Q-in.
WRENCH, socket, %6-in.
( 1 ) Remove Hold-down Assembly.
WRENCH, socket, 9/i6-in.
Remove hold-down assembly by removing the long cap screws which
extend through equalizers to battery support.
RA PD 17630
Figure 90— Removing Battery Hold-Down Assembly
(2) Remove Cables from Battery Terminals.
WRENCH, open-end, ^g-in.
Loosen bolts in clamps around battery terminals; spread clamps
with screwdriver and lift them off battery terminals. NOTE: When
necessary to tighten or loosen the clamped connections at the battery
terminals, use a wrench of the proper size. Care must be taken that the
wrench does not come in contact with any other metal parts of the
148
TM 9-787A
86
ELECTRICAL SYSTEM AND EQUIPMENT
battery or tractor. When removing terminals, remove grounded or
positive terminal first, and when replacing terminals, replace grounded
terminal last.
\:^
RA PD 17654
figure 91— Removing Battery Cable
(3) Remove Batteries. Lift batteries out of support. Keep bat-
teries right side up, and in handling be careful to keep batteries from
touching clothes, as acid may drop on clothes. This acid will destroy
any fabric it touches.
d. Maintenance.
(1) Specific Gravity. Specific gravity readings of each battery
should be taken periodically. Use a hydrometer and test each cell
separately. If readings are below 1.240, the battery is not receiving suf-
ficient charge. (In zero weather there is danger of freezing if readings
are below 1.175; a battery with a specific gravity reading of 1.225 will
freeze at 35 degrees below zero F.) If water must be added oftener than
every two weeks, the electrical system should be adjusted to decrease
the charging rate. Otherwise the battery life will be shortened by over-
charging.
149
TM 9-787A
86
HEAVY TRACTOR Ml
(2) The electrolyte temperature affects the hydrometer reading.
For each 30 F that the electrolyte is above 77 F, add 10 points to the
hydrometer reading to get the true specific gravity. For each 30 F
that the electrolyte is below 77 F, subtract 10 points from hydrometer
reading to get true specific gravity. The above correction is tabulated
in the following table for several electrolyte temperatures:
Electrolyte Correction to Obtain
Temperature True Specific Gravity
+ 122 F Add 15 points
-1- 107 F Add 10 points
-I- 92 F Add 5 points
-j- 77 F No correction
-f ,62 F Subtract 5 points
-i- 47 F " 10 points
-j- 32 F " 15 points
+ 17 F " 20 points
-j- 2 F " 25 points
— 13 F " 30 points
— 43 F " 40 points
EXAMPLE
Hydrometer reads 1.250
Electrolyte temperature 17 F
True specific gravity = 1.250 minus 20 points
True specific gravity = 1.230
When taking hydrometer readings on batteries equipped with "NO-
OVERFLO,"-it will be necessary to return all electrolyte, withdrawn
from battery for purpose of reading, ' by depressing the lead washer.
CAUTION: This washer should be depressed only when returning
electrolyte to cell and not when filling with water.
(3) Adding Water.
(a) If water is added in freezing temperature and battery is not
charged to mix water with electrolyte, the water will remain on top and,
freeze. In a cold climate, water should be added when the battery is
in a warm room so that the battery can be sufficiently charged to
thoroughly mix the water with electrolyte before the water can freeze.
(b) Distilled water should be used.
(c) Do not overfill, as subsequent electrolyte expansion may cause
flooding and damage. The proper filling height is approximately % inch
above top of separators.
(d) The battery may be equipped with a lead washer in each vent
well which is designed to prevent overfilling. Therefore, add water until
it begins to rise into the vent plug well. Draw off any excess in order
to obtain proper level when vent caps are in place.
(4) Vent Plugs. Always keep vent plugs in place except when
filling or taking gravity readings. Vent plugs must be in place while
charging. Be sure hole in vent plug is open.
150
TM 9-787A
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ELECTRICAL SYSTEM AND EQUIPMENT
(5) Keep Batteries Clean and Dry. If wet or dirty, wash with
baking soda solution or ammonia, then with clear water. Be sure vent
plugs are tight befqre washing.
(6) Terminals. Keep terminals tight and clean. If corroded, dis-
connect and clean (wash as in (5) above). Apply a thin coat of COM-
POUND, rust-preventive, light, to terminal and battery posts before re-
placing terminal.
(7) Idle Batteries. An idle battery requires a charge every month
or two or at sufficient intervals to keep the gravity above 1.240.
(8) Temperatures at which electrolyte will freeze with various
specific gravities are as follows:
Actual Specific Gravity Freezing Temperature
1.270 — 96 F
1.255 — 60 F
1.210 — 31 F
1.185 , — 8 F
1.150 + 5 F
1.100 -I- 18 F
(9) The battery is in a hard rubber container. When working around
the battery, remember that all its exposed metal parts are "alive" and
that no metal, tool or wire should be laid across the terminals, as. a
spark or short circuit will result. Sparks and lighted matches or exposed
flames should be avoided near the battery.
e. Installation.
WRENCH, open-end, %6-in. WRENCH, socket, "/le-in., with
extension
(1) Clean All Cables and Cable Terminals. Scrape off all dirt
or corrosion. Coat cable and battery terminals with COMPOUND, rust-
preventive, light.
(2) Install Batteries.
WRENCH, open-end, %6-in.
Place batteries in position. Place large cable from starter switch on
negative post of one battery, positive or ground cable on positive post
of the other battery. Connect the two batteries with the connector cable.
(3) Install Hold-down Assembly.
WRENCH, socket, %6-in. with
extension.
The hold-down device used for securing the batteries in the tractors
gives the battery protection against mechanical shaking, and vibration.
It holds the battery by downward pressure on top of the cell connectors
151
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HEAVY TRACTOR Ml
and terminals instead of holding down on the rubber case. Care should
be exercised in tightening the hold-down to guard against too much
pressure being applied; also that the rubber lining of the hold-down
bears on both the intercell connector (lead strips between cells) and
terminal connectors. In replacing hold-down, check to see that cable
connectors to batteries are tight; that the ungrounded terminals are
clear of any metal part of the hold-down; and that the cables are not
subject to rubbing which will wear off the insulation.
87. GENERATOR.
a. Description. The Delco-Remy generator, Model No. 1105380, is
a 5% 6-inch 2-pole, third-brush, sealed-type unit, with ball bearings in
each end to support the armature. It is used in connection with a Pelco-
Remy voltage regulator, Model No. 5888.
The purpose of the generator is to furnish electrical energy to the
battery where it is stored. Energy drained from the battery is replaced
by generator. The generator is driven by a V-belt from a pulley on the
air compressor; the compressor in turn is driven by a V-belt from a
pulley on the engine crankshaft.
b. Operation. Proper operation of the electrical system depends
largely on a well-charged battery. The battery will be able to supply
enough current to meet the needs of the system only if the generator
is serviced regularly and checked at frequent intervals to determine if
any adjustments or repairs are necessary. These adjustments or repairs
will not be made by the using arm. Minor adjustments may be made
without removing generator from tractor. The charging rate of the
generator is set at from four to eight amperes when the tractor leaves
the factory. This should be sufficient to keep the battery fully charged
under ordinary operating conditions. The voltage regulator serves to
prevent over-charging of the battery.
c. Lubrication. The two hinge cap oilers should be supplied with
8 to 10 drops of OIL, lubricating, engine, SAE 10, after every 64 hours
of operation. Do not oil excessively. Never oil commutator.
d. Trouble Shooting.
(1) Noisy Generator.
Probable Cause Probable Remedy
Loose mounting. Tighten mounting bolts.
Loose pulley. Tighten pulley.
Worn bearings. Notify ordnance personnel.
Dry bearings. Lubricate.
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(2) Excessive Generator Output.
Probable Cause Probable Remedy
Generator field grounded. Locate external ground.
Voltage control unit out of adjust- Notify ordnance personnel.
ment.
Voltage control unit defective. Replace voltage regulator.
Commutator out of round. Notify ordnance personnel.
Burned commutator bars. Notify ordnance personnel.
(3) No Generator Output.
Burned commutator bars. Notify ordnance personnel.
Worn brushes. Notify ordnance personnel.
Sticking brushes. Clean brushes.
Open or short circut in field or Replace unit.
armature.
Loose belt. Adjust for 1-inch slack.
(4) Low Generator Output and Low Battery.
Low brush tension. Notify ordnance personnel.
Brushes sticking. Clean brushes.
Rough, dirty, or greasy commuta- Clean commutator bars.
tor bars.
High mica on commutator. Notify ordnance personnel.
Loose belt. ' Adjust to 1-inch slack.
e. Quick Checks to Determine if Units Are Operating Normally.
( 1 ) A fully charged battery and a low charging rate indicates normal
operation.
(2) A fully charged battery and a high charging rate indicates
faulty generator or voltage regulator operation. Disconnect the lead
from the voltage regulator "F" terminal and if charging rate continues
to be high, generator can be assumed to be at fault. Should the rate
drop off completely, the voltage regulator is at fault.
j[3) It must be remembered that even after the voltage regulator
control has operated and inserted its resistance into the generator field
circuit, it may still be possible for the generator to overcharge the bat-
tery. Under these conditions, it is desirable to reduce the generator out-
put. Notify ordnance personnel.
(4) With a low battery and a low or no charging rate, momentarily
ground the voltage regulator "F" terminal. This should normally cause
the output to increase. If it does not, the generator will probably require
repair, since it is apparently incapable of producing specified output.
If the output does come up, the voltage regulator should be changed.
Loose, connections, defective wiring, or other causes of excessive resist-
153
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HEAVY. TRACTOR Ml
ance in the charging circuit will cause the voltage regulator to operate
and reduce the generator output even though the battery is still in a
low state of charge.
f. Removal.
SCREWDRIVER WRENCH, socket, % ,rin., with
WRENCH, open-end, Va-in. extension
WRENCH, open-end, Vs-in. WRENCH, socket, y4-in.
WRENCH, open-end, y4-in.
( 1 ) Remove Front Fender.
WRENCH, open-end, 2/4 -in. WRENCH, socket, ¥4 -in.
Remove four bolts to remove fender, (fig. 76).
(2) Remove Preheater Intake Assembly.
WRENCH, socket, %6-in., with extension
Open cover by loosening wing nuts, remove cap screw, and remove
preheater intake assembly from engine.
(3) Remove Wires.
SCREWDRIVER
Remove screws to disconnect wires from generator and generator
voltage regulator.
(4) Remove Adjusting Screw.
WRENCH, open-end, Va-in.
Remove cap screw in belt adjusting link.
(5) Remove Generator.
WRENCH, open-end, Ys-in.
Remove the two cap screws holding generator to air compressor
bracket and lift generator out of belt. Generator can now be taken out
from under air compressor bracket.
g. Installation.
SCREWDRIVER WRENCH, open-end, 3/4-in.
WRENCH, open-end, Va-in. WRENCH, socket, %6-in., with
WRENCH, open-end, %6-in- extension
WRENCH, open-end, Ys-in. WRENCH, socket, %-in.
(1) Install Generator on Bracket.
WRENCH, open-end, %6-in.
Hold generator in place and install cap screws in air compressor
bracket.
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ELECTRICAL SYSTEM AND EQUIPMENT
RAPD 17709
Figure 92 — Removing Generator
(2) Connect Wires.
SCREWDRIVER
Connect wires to generator and generator voltage regulator.
(3) Install and Adjust Belt in Pulley.
WRENCH, open-end, Va-in.
Swing generator up and place drive belt in generator pulley. Install
cap screw through washer and adjusting link into generator. Adjust belt
to have from %-inch to 1-inch slack measured halfway between pulleys.
After the generator or control unit is reinstalled on the engine, or at
any time after leads have been disconnected and then reconnected, a
jumper lead should be connected, momentarily, between the battery and
generator terminals of the voltage control unit before starting the engine.
This allows a momentary surge of current from the battery to the gen-
erator which correctly polarizes the generator with respect to the battery
it is to charge.
(4) Install Preheater Intake Assembly.
WRENCH, socket, %6-in-, with extension
Install new gasket on intake if old one is damaged; place assembly
in its proper position; install cap screw and close cover. Tighten wing
nuts.
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HEAVY TRACTOR Ml
(5) Install Fender.
WRENCH, open-end, ^A-'m. WRENCH, socket, 2/4 -in.
Install fender with the four bolts.
h. Generator Belt Removal.
BAR, pry, small WRENCH, open-end, y4-in.
PLIERS WRENCH, socket,, %-in.
WRENCH, open-end, 1/2 -in.
( 1 ) Remove Front Fender.
WRENCH, open-end, 2/4 -in. WRENCH, socket, 2/4 -in.
Remove four bolts and remove fender.
(2) Loosen Generator Belt.
WRENCH, open-end, ,1/2 -in.
Loosen belt by loosening adjusting cap screw in adjusting link.
(3) Remove Air Compressor Pulley.
BAR, pry, small WRENCH, open-end, y4-in.
PLIERS
Remove cotter pin and castellated nut holding drive pulley on com-
pressor crankshaft. Pry pulley from shaft. Generator belt may now be
removed.
i. Generator Belt Installation.
PLIERS WRENCH, open-end, ^-in.
WRENCH, open-end, V2-in. WRENCH, socket, 2/4 -in.
( 1 ) Install Belts. Place generator belt in inside groove of air com-
pressor drive pulley. Install air compressor drive belt in outside groove
of compressor pulley.
(2) Install Air Compressor Pulley.
PLIERS WRENCH, open-end, y4-in.
With drive belts in place, slide pulley on shaft with slot in shaft
in line with key in shaft. Install castellated nut and cotter pin.
(3) Adjust Generator Belt.
WRENCH, open-end, V2-in.
(4) Install Fender.
WRENCH, open-end, ^t-in. WRENCH, socket, y4-in.
88, GENERATOR VOLTAGE REGULATOR.
a. Description. This assembly, mounted on the air compressor
support bracket, consists of a voltage regulating mechanism and a cut-
out relay, both mounted on the same metal base and under the same
cover. This unit operates to decrease the maximum generator output
156
TM 9-787A
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ELECTRICAL SYSTEM AND EQUIPMENT
when the battery approaches full charge. No adjustments of the gen-
erator voltage regulator should be attempted by the operating organi-
zation.
b. Removal.
SCREWDRIVER WRENCH, open-end, yio-in.
(1) Disconnect Wires.
SCREWDRIVER
Remove screws holding the three wires to regulator terminals.
(2) Remove Regulator.
WRENCH, open-end, yie-in.
Remove two cap screws holding regulator to air compressor bracket
and lift oflf voltage regulator.
RA PD 17632
Figure 93— Removing Generator Voltage Regulator
c. Installation.
SCREWDRIVER WRENCH, open-end, %fi-in.
(1) Install Voltage Regulator Unit.
WRENCH, open-end, 346 -in-
Set control unit in place on air compressor bracket and install cap
screws.
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(2) Connect Wires.
SCREWDRIVER
Connect the three wires to the control unit terminals.
89. STARTING MOTOR.
a. Description. This is a Delco-Remy Model No. 1108714, 12-volt
unit, heavy duty, with a Dyer drive operated by a shift lever on the motor.
b. Lubrication. The hinge cap oilers should be supplied with a few
drops of OIL, lubricating, engine, SAE 10, after every 240 hours of
operation.
c. Trouble Shooting.
(1) Slow Starting Motor Speed.
Probable Cause Probable Remedy
Loose connections. Tighten connections.
Dirty connections. Clean connections.
Worn brushes. Notify ordnance personnel.
Arnnature rubbing field coils. Notify ordnance personnel.
Low battery voltage. Check generator and regulator.
(2) Inoperative Starting Motor.
Battery down. Notify ordnance personnel.
Poor connections. Clean and tighten connections.
Burned commutator bars. Notify ordnance personnel.
Open or short circuits in field or Replace unit.
armature.
Defective starter switch. Inspect contacts.
d. If the starting motor does not develop rated torque, and cranks
the engine slowly or not at all, check the battery, battery terminals and
connections, and battery cables. Corroded, frayed, or broken cables
should be replaced, and loose or dirty connections corrected. The start-
ing motor switch should be checked for burned contacts and the switch
contacts cleaned or replaced if necessary. Starting motor failure or
faulty operation, if caused by other than loose and corroded terminals
oi minor adjustments, will not be corrected by the using arm personnel.
e. Removal. •
PLIERS WRENCH, socket, 3/4-in.
WRENCH, open-end, 3/4-in. WRENCH, socket, %-in., with
WRENCH, open-end, ' % (j-in. long extension
( 1 ) Remove Front Fender.
WRENCH, open-end, 3/4-in. WRENCH, socket, s/^.in.
Remove four bolts and remove fender.
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ELECTRICAL SYSTEM AND EQUIPMENT
(2) Disconnect Battery Cable.
WRENCH, open-end, 3/4-in.
Disconnect battery cable from starting motor. Tape the end of cable
to prevent it from touching metal and shorting. Remove other wires on
same post.
(3) Disconnect Starting Motor Rod.
PLIERS
Remove pin from yoke of starting motor lever.
(4) Remove Bolts Holding Starting Motor.
WRENCH, open-end, 1%6-in. WRENCH, socket, %-in., with
long extension
Remove the two cap screws and one bolt holding starting motor to
flywheel housing.
(5) Remove Starting Motor. Jar the starting motor loose by hand
and remove starting motor from tractor.
RA PD 17614
figure 94— Removing Starting Motor
159
TM 9-787A
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HEAVY TRACTOR Ml
f. Installation.
PLIERS WRENCH, socket, 3/4 -in.
WRENCH, open-end, %6-in- WRENCH, socket, %-in., with
WRENCH, open-end, %-in. long extension
WRENCH, open-end, 1%6-in.
( 1 ) Bolt Starter in Place.
WRENCH, open-end, i^e-in. WRENCH, socket, Va-in., with
long extension
Clean off mounting flange of starting motor and housing; set starting
motor in housing and bolt in place.
(2) Install Starting Motor Rod.
PLIERS
WRENCH, open-end, ^g-in.
Connect starting motor rod on shift lever with pin. Adjust cap screw
on shift lever as follows: Screw the adjusting cap screw in toward the
lever so that the switch contacts do not touch when the lever is pushed
all the way forward. Place the shifter lever in full forward position
(the starting motor pinion will be against the stop). Back the cap
screw out so that the switch contacts close. Pull the starting motor
shift lever back and turn the adjusting screw out an additional twO'
turns. Lock the nut.
(3) Connect Battery Cable.
WRENCH, open-end, y4-in.
Connect battery cable, ammeter wire, and electric brake wire to
starting motor switch post. Put on washer and nut and tighten.
90. AMMETER.
a. Description. The ammeter needle registers on the dial the amount
of current being delivered to the battery when the engine and generator
are running, or discharge from the battery when the engine is not run-
ning. If generator operation is normal, the needle swings towards the
plus ( + ) side of the scale. When engine is not running, current used
by electrical equipment discharges the battery and the needle swings
towards the minus (— ) side of the scale.
b. When the ammeter registers too high a charging rate (over eight
amperes on plus side of scale) with the engine running at normal speed,
generator or voltage regulator is not functioning properly. If it registers
zero with the engine running at normal speed and no electrical equip-
ment turned on, it indicates one of the following:
(1) Batteries are fully charged — no correction necessary.
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ELECTRICAL SYSTEM AND EQUIPMENT
(2) Generator is not working — check generator (par. 87); replace if
necessary.
(3) Voltage control is inoperative — change voltage regulator.
(4) A wire may be loose or broken — inspect wiring.
(5) Ammeter may be faulty — replace ammeter.
c. Removal.
SCREWDRIVER WRENCH, open-end, ^/s-in.
( 1 ) Remove Ammeter from Dash Panel.
SCREWDRIVER
Remove the three cross-rrecessed screws holding ammeter in panel
and remove ammeter from panel.
(2) Remove Wires.
WRENCH, open-end, %-in.
Remove the six wires from two terminals on back of ammeter by
removing the nuts and washers from terminals. Tag the wires so they
may be reinstalled on the correct terminals of the new ammeter.
d. Installation.
SCREWDRIVER WRENCH, open-end, %-in.
(1) Connect Wires.
WRENCH, open-end, %-in.
Connect wires to new ammeter, placing the two wires on left-hand
terminal and four wires on right-hand terminal. Tighten nuts.
(2) Install Ammeter.
SCREWDRIVER
Set ammeter in panel and install the three cross-recessed screws.
(3) Test Ammeter. Start engine and see that all electrical equip-
ment operates properly.
91. HOUR METER.
a. Description. The engine hour meter is located on the dash to
the right of the instrument panel and registers the total number of hours
that the engine has operated. A pressure switch connected to the oil
pressure gage is operated by pressure of the oil to the gage when
engine is started. One wire from the pressure switch is connected to
the hour meter and the other to the ammeter. A ground wire from the
hour meter is connected to the temperature gage. Paragraph 25 gives
instructions on how to read the hour meter.
b. If the hour meter becomes inoperative, it may be due to either a
faulty pressure switch or to the meter itself. Check for broken wires and
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TM 9-787A
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HEAVY TRACTOR Ml
loose connections before replacing either. Do not attempt any repair
of either the switch or hour meter. Check the pressure switch first by
removing the two wires from the terminals of the switch and connect-
ing the two ends. If the hour meter begins to operate immediately, the
pressure switch should be replaced. If it does not, the hour meter should
be replaced.
c. Removal.
PLIERS
SCREWDRIVER
WRENCH, open-end, %6-in.
(1) Remove Panel FROM Dash.
SCREWDRIVER
Remove the four cross-recessed screws holding panel to dash and
pull panel out of dash carefully.
RA PD 17602
figure 95— Removing Screws from Instrumenf Panel
(2) Disconnect Wires.
SCREWDRIVER
Disconnect the wire leading from the hour meter to temperature gage.
Remove the wire seal and cover from the pressure switch and discon-
nect the wire leading from pressure switch to hour meter.
162
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ELECTRICAL SYSTEAA AND EQUIPMENT
(3) Remove Hour Meter.
SCREWDRIVER
Remove the three cross-recessed screws holding the hour meter to
dash and remove hour meter.
(4) Remove Pressure Switch.
WRENCH, open-end, %a-m.
Disconnect wire leading from pressure switch to ammeter, hold elbow
with pliers, and unscrew pressure switch from the side outlet elbow.
d. Installation.
PERMATEX or white lead SCREWDRIVER
PLIERS WRENCH, open-end, %6-in.
(1) Install Pressure Switch
WRENCH, open-end, %«-in.
Coat threads of pressure switch with permatex or white lead and
screw into side outlet elbow tightly.
(2) Install Hour Meter.
SCREWDRIVER
Place hour meter in hole in dash and secure with the three cross-
recessed screws.
(3) Connect Wires.
SCREWDRIVER
Connect the short wire on hour meter to one terminal of pressure
switch. Connect the long wire to temperature gage. Connect the wire
from the ammeter to other terminal of pressure switch. Install cover
on switch and install seal wire.
(4) Install Instrument Panel.
SCREWDRIVER
Place panel back in dash and secure with the four cross-recessed
screws.
(5) Test for Operation. Start engine and watch small hand at
top left of dial of hour meter. As soon as oil pressure rises to five pounds,
this hand should start to rotate.
92. AIR HEATER.
a. Description. The air heater is essentially a small, pressure oil
burner with electric ignition. The burner proper is mounted in the
engine air box and obtains the necessary air for combustion from the
blower. The flame-heated air is discharged directly into the engine
163
TM 9-787A
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HEAVY TRACTOR Ml
cylinders. The air heater consists of two assemblies; one unit comprises-
the pressure pump mounted on the dash, and the other unit consists
of a burner nozzle, filter, ignition coil, and ignition points. The air
heater replaces one of the hand hole cover plates nearest the center
of the engine. The hand pump on the dash supplies fuel under pressure
to the burner unit where it is ignited as it is sprayed through the nozzle.
A button switch on dash is used when air heater is to be operated. For
operation of the air heater, refer to paragraph 11.
BODY-
IGNITION COIL
INSULATOR ASSEMBLY
RA PD 56390
Figure 96— Air Heater Parts
h. The vibrator in the air heater should buzz when the button switch
is depressed. If no buzz can be heard, it is an indication that no current
is being supplied to the coil or the vibrator points are stuck or burned.
A unit that fails to arc at the electrodes may often be made to operate
by cleaning and drying the electrodes.
c. Removal of Air Heater Burner Unit.
WRENCH, socket, %6-in., with
extension.
WRENCH, open-end, Ys-in.
WRENCH, open-end, yie-in.'
WRENCH, socket, Vi-in.
( 1 ) Disconnect Fuel Line.
WRENCH, open-end, %6-in.
Disconnect fuel line at rear of check valve.
(2) Remove Cover.
WRENCH, socket, 1/2-in.
Remove the two cap screws holding cover to unit and remove cover.
164
TM 9-787A
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ELECTRICAL SYSTEM AND EQUIPMENT
(3) Disconnect Wire from Coil.
WRENCH, open-end, s/s-in.
Disconnect the wire leading from air heater switch to coil.
(4) Remove Air Heater Body.
WRENCH, socket, %6-in. with
extension
Remove the special cap screw holding burner imit and remove air
heater body.
RA PD 17639
Figure 97— Removing Air Heater Burner Unit
d. Installation of Air Heater Burner Unit.
WRENCH, open-end, ys-in. WRENCH, socket, %a-in., with
WRENCH, open-end, ym-in. extension
WRENCH, socket, 1/2 -in.
( 1 ) Install Body. Clean off all old gaskets and use new ones. Install
unit in place with the special cap screw.
(2) Connect Wire to Coil.
WRENCH, open-end, ^/s-in.
165
TM 9.787A
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HEAVY TRACTOR Ml
(3) Install Cover.
WRENCH, socket, Va-in.
Use a new felt gasket, if necessary, and bolt cover in place with the
two cap screws. Install lower cap screw through clip holding fuel line
check valve.
(4) Connect Fuel Line.
WRENCH, open-end, %6-in.
Connect the fuel line to rear of check valve.
e. Removal of Air Heater Pump Assembly.
PLIERS WRENCH, open-end, s/g-in.
WRENCH, open-end, yie-in. WRENCH, open-end, ys-in.
WRENCH, open-end, %6-in. WRENCH, open-end, i%6-in.
(1) Close Fuel Shut-off Valve at Tank.
(2) Disconnect Fuel Lines.
WRENCH, open-end, yia-in. WRENCH, open-end, s/s-in.
WRENCH, open-end, fig-in. WRENCH, open-end, ys-in.
Disconnect both intake and discharge lines from pump.
(3) Remove Pump Plunger and Pump Body.
PLIERS WRENCH, open-end, %-in.
Hold the pump to keep it from turning, removing the pump plunger
nut and pull pump plunger from pump body. Pump body may now
be pushed out to rear of dash.
f. Installation of Air Heater Pump Assembly.
PLIERS WRENCH, open-end, s/g-in.
WRENCH, open-end, yig-in. WRfeNCH, open-end, %-in.
WRENCH, open-end, %6-in. WRENCH, open-end, i%6-in.
(1) Install Pump Body. Remove the pump plunger nut from re-
placement assembly and pull plunger out. Screw jam nut back on threads
as far as possible. Pldce the threaded end of pump body through dash
from inside.
(2) Install Plunger.
PLIERS WRENCH, open-end, i %6-in-
WRENCH, open-end, ^s-in.
Soften the pump plunger leathers with OIL, lubricating, engine, SAE
10, and carefully enter the plunger into the pump body so that the
leathers are not damaged. Tighten the pump plunger nut; then tighten
jam nut against inside of dash.
166
TM
9-787A
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ELECTRICAL SYSTEM AND EQUIPMENT
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HEAVY TRACTOR Ml
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168
TM 9-787A
92-93
ELECTRICAL SYSTEM AND EQUIPMENT
(3) Connect Fuel Lines.
WRENCH, open-end, Vm-m. WRENCH, open-end, %-in.
WRENCH, open-end, »/i6-in. WRENCH, open-end, '/s-in.
Connect intake and discharge fuel lines; open the fuel shut-off valve
and operate the pump a few times to make sure it operates properly and
does not leak.
g. Removal of Air Heater Switch.
PLIERS SCREWDRIVER
(1) Remove Switch from Dash.
PLIERS
Hold the switch body to keep it from turning; remove the round
knurled lock nut that is tight against dash, and remove switch from dash.
(2) Remove Wires.
SCREWDRIVER
Disconnect the wires from the switch by removing the two screws
holding them.
h. Installation of Air Heater Switch.
PLIERS WRENCH, open-end, 3/4-in.
SCREWDRIVER
(1) Install Wires on Switch.
SCREWDRIVER
Connect the two wires to the switch with the two screws.
(2) Install Switch.
PLIERS WRENCH, open-end, y4-in.
Insert the threaded end of switch through the hole in dash with button
towards operator, and tighten in place with the knurled nut. Tighten
jam nut.
93. LIGHT SWITCH.
a. Description. The light switch is of the push-pull type with a
spring stop to control its three positions. It may be pulled out to the
first position (blackout lights) without depressing the latch button. For
the other two positions (service lights and service stop light), the latch
button must be depressed to pull switch out.
b. Removal.
PLIERS WRENCH, open-end, V2-in.
SCREWDRIVER WRENCH, open-end, 3/4 -in.
(1) Remove Switch Knob.
PLIERS SCREWDRIVER
Loosen set screw in knob and unscrew knob from shaft.
169
TM 9-787A
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HEAVY TRACTOR Ml
BLACKOUT CONTRCl r-l.TTONi -\
RA PD 56395
figure 100— Blackout Control on Light Switch
(2) Remove Blackout Control Assembly.
WRENCH, open-end, y2-in.
Remove lock screw from side of blackout control assembly; depress
button and pull assembly from dash.
(3) Remove Switch.
WRENCH, open-end, V^-in.
Remove switch mounting nut and pull light switch assembly from
dash.
(4) Remove Wires.
SCREWDRIVER
Remove wires by removing the screws from terminals on switch. Tag
wires for identification.
c. Installation.
PLIERS
SCREWDRIVER
WRENCH, open-end, Va-in.
WRENCH, open-end, y4-in.
(1) Connect Wires to Switch.
SCREWDRIVER
Place wires on terminals according to tags on wires or refer to wiring
diagram (fig. 105).
170
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ELECTRICAL SYSTEM AND EQUIPMENT
Figure 101— Removing Light Switch
171
RA PD 41093
TM 9-787A
93-94
HEAVY TRACTOR Ml
(2) Install Switch IN Dash.
WRENCH, open-end, V^-in.
Insert shaft of switch through dash with shaft towards operator. Install
mounting nut and lock washer; tighten. Notches on shaft should be
to the left.
(3) Install Blackout Control Assembly.
WRENCH, open-end, Va-in.
Slip blackout control assenibly on shaft, holding latch button down.
Latch button should point up. Hold assembly against dash; place lock
washer on lock screw; install and tighten.
(4) Install Knob.
PLIERS SCREWDRIVER
Screw knob tight on shaft and tighten set screw.
94. PANEL LIGHT.
a. General. The panel light is similar to those ordinarily used on
cars and trucks. It is mounted on the instrument panel in dash and is
controlled by a separate push-pull type switch. The panel light throws
sufficient light on the operating instruments to make them easily read
during night operation. The main light switch must be pulled out be-
fore panel light will turn on.
b. Removal of Panel Light Bulb.
SCREWDRIVER
(1) Remove Shield.
SCREWDRIVER
Remove the two screws holding shield to bracket and pull off shield.
Glass inside of shield will come off with shield.
(2) Remove Bulb.
Push in' slightly on bulb and turn it to the left. Bulb can now be
pulled out of socket.
c. InBtallation of Panel Light Bulb.
SCREWDRIVER
(1) Install Bulb.
Insert bulb in socket with bulb turned so that the two points on biilh
coincide with the two slots in socket. Push bulb in far enough so that
the two points may be turned to the right into locking notches.
(2) Install Shield.
SCREWDRIVER
Be sure rubber ring is in place. Push shield on, around bracket, and
install the two screws.
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95. SERVICE LIGHTS.
a. Description. The lighting system is 12-volt throughout with the
exception of the panel light. Headlights are mounted one on each side
of radiator and are protected with guards. Small blackout lamps are
mounted to top of headlight guards. Some tractors in the field are not
equipped with blackout lights. Blackout lights will be provided for them
as soon as possible. Rear lights are combined stop and taillights and
blackout lights. The trailer brake control system is wired so that the
lights on trailer work in conjunction with tractor lights. Lights are con-
trolled by main light switch (par. 93).
b. Removal of Headlight and Bulb.
SCREWDRIVER
WRENCH, socket, %6-in.
WRENCH, socket, ^4-in.
RA PD 17269
Figure 102— Removing Headlight Guard
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( 1 ) Remove Guard.
WRENCH, socket, 3/4-in.
Remove guard by removing four cap screws holding guard to brackets
on radiator shell. Blackout lights are fastened to guard. Pull wire to
blackout light from socket as guard is removed.
(2) Remove Headlight.
WRENCH, socket, %e-in.
Unscrew retaining nut and remove wire from bottom of headlight.
Remove two cap screws holding light to radiator shell and remove head-
light.
(3) Remove Bulb.
SCREWDRIVER
Loosen screw in clamp around lens and remove clamp moulding as-
sembly and lens. Push in on bulb, turn bulb to left and pull out bulb.
NOTE: Omit second step if only bulb is to be removed.
c. Installation of Headlight and Bulb.
SCREWDRIVER. WRENCH, socket, 3/4-in.
WRENCH, socket, %6-in.
( 1 ) Install Bulb.
Insert a 12-volt, 32 cp-bulb in socket. Push bulb in and turn it to
right into locking notches.
(2) Install Lens.
SCREWDRIVER
With lens in clamp moulding assembly, work clamp onto headlight
and tighten screw in clamp.
(3) Install Headlight.
WRENCH, socket, %e-in-
Hold headlight against radiator shell and install cap screws. Connect
headlight wire by inserting plug on end of wire in socket of headlight
and screw retaining nut on socket.
(4) Install Guard.
WRENCH, socket, ^-in.
Hold guard close to headlight and plug blackout light wire into
connector. Place guard over headlight and on the brackets on radiator
shell and install cap screws.
d. Removal of Blackout Light and Bulb.
SCREWDRIVER WRENCH, socket, %e-in.
WRENCH, open-end, 1/2-in. WRENCH, socket, 3/4-in.
WRENCH, open-end, %6-in.
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ELECTRICAL SYSTEM AND EQUIPMENT
(1) Remove Headlight Guard.
WRENCH, socket, y4-in.
Remove four cap screws holding guard to brackets on radiator shell
and remove guard. Pull blackout light wire from connector as guard is
removed.
(2) Remove Blackout Light Guard from Headlight Guard.
WRENCH, open-end, %6-in. WRENCH, socket, %6-in.
Remove bolt from blackout light guard and headlight guard and
remove blackout light guard.
(3) Remove Blackout Light.
WRENCH, open-end, 1/2-ia
• Remove nut holding blackout light on headlight guard and slip it off,
over wire. Remove blackout light from guard.
Figure 103— Removing Bfackout Headlight
(4) Remove Bulb.
SCREWDRIVER
Remove screw holding lens. Remove lens, push bulb in and turn it
to left out of locking notches and pull bulb out of socket. NOTE: For
removal of bulb only, this is the only step necessary.
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e. Installation of Blackout Light and Bulb.
SCREWDRIVER WRENCH, socket, %e-in-
WRENCH, open-end, Va-in. WRENCH, socket, 3/4-in.
WRENCH, open-end, %6-in.
( 1 ) Install Bulb.
Insert bulb in socket of light. Push bulb in far enough to engage in
locking notches and turn bulb to the right.
(2) Install Lens.
SCREWDRIVER
Place lens on light and secure with screw.
(3) Install Light.
, WRENCH, open-end, Va-in.
Insert wire and threaded part of light assembly through hole in
headlight guard, install nut, and tighten.
(4) Install Guard.
WRENCH, open-end, %6-in. WRENCH, socket, s/ig-in.
Place blackout light guard on headlight guard and install outside
bolt.
(5) Install Assembly on Tractor.
WRENCH, socket, 3/4-in.
Insert blackout light wire into connector and bolt headlight assembly
to tractor.
f. Removal of Rear Lamp Assembly.
SCREWDRIVER WRENCH, open-end, %6-in.
WRENCH, open-end, Va-in. WRENCH, socket, %6-in.
( 1 ) Disconnect Wires.
Slip rubber boots off connections at rear of lamp, turn the plugs and
pull them from their sockets.
(2) Remove Lamp.
WRENCH, open-end, Va-in.
Remove the two nuts holding lamp to guard bracket an4 remove
larpp from bracket.
(3) Remove Bracket.
WRENCH, open-end, %6-in. WRENCH, socket, %6-in.
Remove four bolts holding lamp guard to rear street plate box and
remove guard. NOTE: Replacement of lamp assembly requires only
first two steps.
(4) Remove Individual Lights.
SCREWDRIVER
Remove two screws holding rim of light, remove rim and pull lights
from sockets. NOTE: To replace either light, it is necessary to perform
this step only.
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ELECTRICAL SYSTEM AND EQUIPMENT
, -/'J^
■^
Figure 104— Removing Lights from Rear Lamp
g. Installation of Rear Lamp Asgembly.
SCREWDRIVER WRENCH, open-end, %6-in.
WRENCH, open-end, y2-in. WRENCH, socket, %6-in-
(1) Install Lights.
SCREWDRIVER
Insert lights in their respective sockets and install rim and screws.
(2) Install Lamp in Guard.
WRENCH, open-end, Va-in.
Insert bolts at rear of lamp through holes in guard and install and
tighten nuts.
(3) Install Assembly to Box.
WRENCH, open-end, %a-m. WRENCH, socket, %ii-in.
Hold assembly against end of street plate box. Install bolts and
tighten them.
(4) Connect Wires.
Insert plugs on ends of wires in sockets. Push them in far enough
" so that plugs can be turned to engage in locking notches. NOTE : The
plug with two wires should be installed in upper socket of left lamp.
Slip rubber boots over connections.
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HEAVY TRACTOR Ml
h. Stop Light Switch. This is a lever-type switch bolted under-
neath floor plate and is operated by the master clutch lever. When
clutch lever is pushed forward to release the clutch, the lower end of
the lever actuates stop light switch lever and stop light is lighted.
(1) Removal.
SCREWDRIVER WRENCH, socket, %Q-m.
WRENCH, open-end, %6-in.
(a) Remove Switch trom Floor Plate.
WRENCH, open-end, %6-in. WRENCH, socket, ^e-in.
Remove the two bolts from which switch is suspended. These bolts
are those just back of the rear end of slot in floor plate in which master
clutch lever works. Switch can now be lifted up through clutch lever
slot.
(b) Remove Wires from Switch.
SCREWDRIVER
Remove two screws holding wires to switch. Tape wires as they are
removed.
1 (2) Installation.
SCREWDRIVER WRENCH, socket, %a-in.
WRENCH, open-end, % g-in.
(a) Connect Wires to Switch.
SCREWDRIVER
Connect one wire to each terminal of switch with screws.
(b) Install Switch.
WRENCH, open-end, %6-in. WRENCH, socket, %6-in.
Lower switch and wires down through master clutch lever slot; hold
in position with holes back of slot, and install bolts. Clutch lever should
be pulled back, engaging clutch, when installing switch. End of switch
lever should point toward center of tractor.
96. WIRING.
a. The schematic diagram of the wiring of the tractor shown in
figure 105 shows the length of the wires and their distinguishing colors.
After a tractor has been in use for a length of time, it may be necessary
when replacing a wire or wires to strip the loom of a harness of wires
back a little way to expose the wires and determine their coloring. The
entire system with the exception of electric trailer brakes can be re-
wired from this diagram. See Figure 111 for schematic wiring diagram
of electric trailer brake system.
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E
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e
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E
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w
I
a
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b. Replacement of wires is seldom necessary unless the wires are
destroyed by fire or like causes. A broken wire can be repaired easily
by stripping about an inch of insulation off the two broken ends, twist-
ing the two ends together and wrapping the spliced section with adhesive
or friction tape. Any portions of the wire that have the insulation rubbed
off through rubbing on some part of tractor should be wrapped with tape
to prevent short circuits.
c. There are no fuses in the wiring system of the tractor. A thermal
cut-out unit on the main light switch automatically shuts off current
from circuit in which a short circuit occurs. After the short circuit is
located, the wire shorted may be pulled from the closest connector be-
tween it and switch and only that part of the electrical system will be
inojjerative. Operation can continue then if time or facilities for repair
are lacking. However, the cause of shorting should be remedied as soon
as possible so entire system will be in operating condition.
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97
Section XVI
NONELECTRICAL INSTRUMENTS
Paragraph
Lubricating oil pressure gage 97
Fuel pressure gage 98
Temperature gage 99
Air pressure gage 100
Mile meter 101
97. LUBRICATING OIL PRESSURE GAGE (fig. 10).
a. Description. The lubricating oil pressure gage is located in the
instrument panel. A dial facing the operator registers the pressure of
the lubricating oil delivered to the engine. At engine operating speed
and temperature, the oil pressure should be between 25 and 35 pounds.
If pressure falls below 25 pounds (at full throttle), the cause should
be immediately determined.
b. Removal.
PLIERS WRENCH, open-end, s/ig-in.
SCREWDRIVER
( 1 ) Remove Instrument Panel.
SCREWDRIVER
Remove the four cross-recessed screws holding panel to dash and
pull panel back carefully until fittings at rear of oil pressure gage can
be reached.
(2) Remove Gage.
PLIERS WRENCH, open-end, %6-in.
SCREWDRIVER
Remove the three cross-recessed screws holding gage in panel. Hold
pipe elbow with pliers and unscrew lubricating oil pressure gage from
elbow with %8-inch open-end wrench.
c. Installation.
PERMATEX or WHITE SCREWDRIVER
LEAD WRENCH, open-end, %6-in.
PLIERS
(1) Install Gage in Pipe Elbow.
PERMATEX or WHITE WRENCH, open-end, %6-in.
LEAD
PLIERS
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W-
RA PD 17603
Figure 106— Removing Lubricating Oil Pressure Gage
Coat threads of gage with permatex or white lead and screw into pipe
elbow. Tighten, using pliers to hold elbow; the wrench to turn gage.
Turn so that the gage dial is in correct position and the hour meter
pressure switch stands up.
(2) Install Gage in Panel.
SCREWDRIVER
Secure gage to panel with the three cross-recessed screws.
(3) Install Panel in Dash.
SCREWDRIVER
Work panel back into dash and secure with the four cross-recessed
screws. Start engine and check operation of lubricating oil pressure gage.
98. FUEL PRESSURE GAGE.
a. Description (fig. 106). The fuel pressure gage is similar to the
lubricating oil pressure gage. The dial registers the fuel pressure to the
injectors. A fuel line from a point between the third stage fuel filter
and the intake manifold leads to the gage.
b. Normal fuel pressure is from 20 to 30 pounds and may be even
higher than 30 pounds. In the event that high fuel pressure is
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NONELECTRICAL INSTRUMENTS
experienced, remove fuel tank filler cap and, with engine running at full
throttle, observe if a full stream of fuel is returning into tank. If not,
there may be clogged filters in the system or injectors, or the restricted
fitting at rear end of return fuel manifold may be clogged. If there is a
good stream of fuel returning into tank, no correction is necessary and
the high fuel pressure will cause no damage (sec. XII).
c. Removal.
SCREWDRIVER WRENCH, open-end, s/g-in.
WRENCH, open-end, %8-in. WRENCH, open-end, ys-in.
(1) Remove Instrument Panel from Dash.
SCREWDRIVER
Remove the four cross-recessed screws holding panel to dash and
pull panel out of dash far enough to reach fuel lines with wrenches.
(2) Disconnect Fuel Line.
WRENCH, open-end, Vs-in. WRENCH, open-end, %-in.
Disconnect fuel line, holding coupling with Vs-inch open-end wrench,
and turn nut off with %-inch, open-end wrench.
(3) Remove Restriction Unit.
WRENCH, open-end, %6-in-
Unscrew restriction unit out of elbow.
(4) Remove Gage.
SCREWDRIVER
Remove the three cross-recessed screws holding gage in panel and
remove gage. Remove elbow from gage.
d. Installation.
PERMATEX WRENCH, open-end, Vs-in.
SCREWDRIVER WRENCH, open-end, '/s-in.
WRENCH, open-end, %6-in.
(1) Install Elbow on Gage.
PERMATEX or WHITE PLIERS
LEAD
Coat threads of elbow with permatex or white lead and screw elbow
into gage.
(2) Install Gage in Instrument Panel.
SCREWDRIVER
Set gage in place in panel and secure with three cross-recessed
screws.
(3) Install Restriction Unit.
PERMATEX or WHITE WRENCH, open-end, %6-in.
LEAD
Coat threads of unit with permatex or white lead and screw into
elbow. Restriction unit and elbow should point towards the right.
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(4) Connect Fuel Line.
WRENCH, open-end, s/s-in. WRENCH, open-end, Vs-in.
Screw connector into restriction unit and then connect fuel line with,
nut on end of line.
(5) Install Panel in Dash.
SCREWDRIVER .
Work wires and lines back through panel opening and install screws
in panel and dash.
99. TEMPERATURE GAGE.
a. Description. The temperature gage assembly consists of a thermo
gage tube, cable, and dial gage. The dial registers the temperature of the
water in the engine. It is actuated by the tube which is mounted in the
rear of the water manifold.
b. Removal.
SCREWDRIVER WRENCH, open-end, n/ie-in.
WRENCH, open-end, %6-in.
( 1 ) Drain Cooling -System. Open drain cock in lower connector
elbow and drain out enough water to bring level below water manifold.
(2) Remove Clip AND Cap Screw.
WRENCH, open-end, ^le-in.
Remove cap screw from balance weight housing holding clip and
pipe.
(3) Remove Thermo Gage Tube.
WRENCH, open-end,' "/i6-in.
Remove thermo gage tube from rear of water manifold.
(4) Remove Temperature Gage Assembly.
SCREWDRIVER
Remove three cross-recessed screws holding gage in panel, and remove
gage, cable, thermo gage tube through cowl and dash, as an assembly.
c. Installation.
SCREWDRIVER WRENCH, open-end, n/ie-in.
WRENCH, open-end, %6-in.
( 1 ) Install Gage in Panel.
SCREWDRIVER
Insert end of cable through temperature gage hole in dash panel, then
through hole in cowl. Place gage in panel and install the three cross-
recessed screws.
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NONELECTRICAL INSTRUMENTS
(2 ) Install Thermo Gage Tube in Water Manifold.
WRENCH, open-end, ' V, g-in.
Insert tube into hole in rear of water manifold, screw in and tighten
retaining nut.
(3) Install Clip and Cap Screw.
WRENCH, open-end, % g-in.
Place clip around cable; cap screw through clip and into side hole in
balance weight cover, and tighten.
(4) Add Water to Cooling System.
100, AIR PRESSURE GAGE (fig. 10).
a. General. The air pressure gage registers pressure of air in trailer
air brake control system. It is important to watch gage to see that air
pressure rises after engine is started to be sure the trailer air brake sys-
tem is in operating order.
b. Removal.
WRENCH, open-end, 1/2 -in. WRENCH, open-end, s/s-in.
WRENCH, open-end, %6-in.
( 1 ) Disconnect Air Line to Gage.
WRENCH, open-end, % «-in. WRENCH, open-end, %-m.
Open petcock on bottom of air reservoir to relieve pressure. To dis-
connect air line at gage, hold coupling from turning with smaller wrench
and turn nut ofif with larger wrench.
( 2 ) Remove Retaining Nuts.
WRENCH, open-end, 1/2 -in.
Remove nuts from bolts through bracket at rear of gage and remove
air pressure gage from dash.
c. Installation.
WRENCH, open-end, 1/2-in. WRENCH, open-end, Vs-in.
WRENCH, open-end, % g-in.
(1) Install Gage in Dash.
WRENCH, open-end, 1/2 -in.
Place gage in hole in dash with bolts on gage through bracket back
of dash. Install nuts and tighten to hold gage firmly.
(2) Connect Air Line.
WRENCH, open-end, 9/i«-in. WRENCH, open-end, s/s-in.
Start nut on coupling, hold coupling with smaller wrench and tighten
with larger wrench. Close petcock on air reservoir.
101. MILE METER (fig. 10).
a. General. The mile meter is driven by a flexible shaft inside a
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housing extending from the back of meter into the transmission case
to a gear on the front end of the lower transmission shaft.
h. If the mile meter becomes inoperative, make the following check:
(1) With pliers, disconnect the cable from the bottom of the meter
by unscrewing the retainer nut which holds the shaft housing to the
meter.
(2) Put the tractor in motion and observe whether the shaft turns
inside its retainer. If it does, the mile meter should be replaced. If it
does not, the shaft is broken or the gears at the lower end of shaft are
stripped. In this case, the drive assembly will have to be replaced. Re-
placement of meter can be done by the using arm, but not replacement of
the drive assembly.
c. Removal of Meter.
PLIERS SCREWDRIVER
( 1 ) Disconnect Cable.
PLIERS
Loosen retainer nut, which holds end of housing to bottom of meter,
with pliers and unscrew it from meter. Pull cable and housing from meter.
(2) Remove Meter FROM Dash.
SCREWDRIVER
Remove the three cross-recessed screws which hold meter to dash and
pull mile meter from dash.
d. Installation.
PLIERS SCREWDRIVER
( 1 ) Install Meter in Dash.
SCREWDRIVER
Place meter in hole in dash and install three cross-recessed screws
through flange of meter, and into dash.
(2) Connect Drive Cable AND Housing.
PLIERS
The end of drive cable is square and fits into a square socket in meter
drive. Insert the cable in meter, hold up on cable housing and screw
retainer nut on meter. Tighten lightly with pliers.
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Section XVII
ELECTRIC AND AIR TRAILER BRAKE CONTROL SYSTEM
* Paragraph
Description 102
Air brakes . 103
Electric brakes 104
102. DESCRIPTION.
a. The trailer brake control system on the tractor is designed to
operate the brakes on vehicles to be pulled, and which might be equip-
ped with either air or electric brakes. The control on the right steering
clutch lever operates both the air brake valve and the electric brake
controller; however, only one of the brake systems operates at one time
(fig. 10).
b. In addition to the steering clutch lever control, an auxiliary hand
operated air valve control mounted on the tractor dash may be used to
apply the trailer air brakes. A rheostat mounted on the tractor dash
is provided to regulate the intensity of brake application to meet vary-
ing brake requirements when the electric brakes are to be used.
103. AIR BRAKES.
a. Air Compressor. The compressor is a two-cylinder, Bendix-
Westinghouse Model No. 2 — US — 7V4 — VW. It is mounted on a
bracket which is bolted to the cylinder block. The compressor is water-
cooled; has its own oil supply system and pumping system; and is driven
by belts from a pulley on the engine crankshaft. An air governor
regulates the air reservoir pressure and when this reaches 105 pounds
per square inch, the governor opens an unloader valve. This permits
the air displaced by the upward movement of the piston to pass from
one cylinder to the other without compression.
b. Maintenance of Air Compressor.
(1) The air compressor lubricating oil should be drained and
refilled each time the oil in engine crankcase is changed. Use an
engine oil of the same viscosity as is used in engine.
(2) Remove the air filter (fig. 107) by removing tw6 cap screws
holding it to compressor (use a %6-inch open-end wrench), and wash
mat with SOLVENT, dry-cleaning, or fuel oil, after every 100 hours of
operation, or oftener if operating under extremely dusty conditions. Satu-
rate the filter mat with OIL, lubricating, engine, SAE 10, before reinstalling.
(3) Oil the unloader rocker arm fulcrum pin with OIL, lubricating,
engine, SAE 10, after every 100 hours of operation.
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RA PD 17496
Figure 107— Removing Filter from Compressor
(4) Adjust unloader valve clearance after every 200 hours of opera-
tion as follows:
GAGE, feeler WRENCH, open-end, Yj g-in.
WRENCH, open-end, 1/4-in.
(a) Loosen Lock Nut.
WRENCH, open-end, '%6-in.
Loosen lock nut under rocker arm on adjusting screw.
WRENCH, open-end, yie-in.
(b) Adjust clearance.
GAGE, feeler
WRENCH, open-end, V4-in.
Turning adjusting screw to right (clockwise) increases clearance
and turning it to left (counterclockwise) decreases clearance between
rocker arm and valve stem. Adjust clearance with feeler gage to 0.010-
inch to 0.015-inch. Tighten lock nut and check clearance again to
determine if clearance changed when lock nut was tightened.
(5) The compressor discharge line (fig. 109) should be removed
periodically and cleaned of carbon deposits or other forms of stoppage.
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RA PD 17262
Figure 108— Adjusting Compressor Valve Clearance
(6) The compressor drive belt should be adjusted periodically.
c. Removal of Air Compressor.
WRENCH, open-end, %-in.
WRENCH, open-end, ^%2-in.
WRENCH, open-end, %-in.
( 1 ) Disconnect Air Lines.
WRENCH, open-end, %-in. WRENCH, open-end, %-in.
Disconnect air lines from compressor and remove the cap screw hold-
ing the air line tubing clips to air compressor support bracket.
(2) Disconnect Water Lines.
WRENCH, open-ehd, Vs-in.
Disconnect inlet and outlet water lines from air compressor.
(3) Remove Air Compressor.
WRENCH, open-end, %-in. WRENCH, open-end, -%:.-in.
Remove two cap screws and two bolts holding air compressor unit
to support bracket, slip belts from pulley, and lift off air compressor.
d. Installation of Air Compressor.
WRENCH, open-end, Vs-in. WRENCH, open-end, ys-in.
WRENCH, open-end, ^%2-in.
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WATER OUTLET LINE-
HEAVY TRACTOR Ml
AIR DISCHARGE LINE
RA PD 56391
figure 109— Removing Air Compressor
WRENCH, open-end, ^s/g-g-in.
( 1 ) Install Unit to Support Bracket.
WRENCH, open-end, %-in.
Set air compressor on support bracket, slip generator belt and drive
belt on pulley and install two bolts and two cap screws.
(2) Connect Water Lines.
WRENCH, open-end, Ys-in.
Connect the two water lines to head of air compressor.
(3) Connect Air Lines.
WRENCH, open-end, s/s-in. WRENCH, open-end, ^s-in.
Connect the two air lines to compressor.
(4) Adjust Air Compressor and Generator Drive Belts. Ad-
just air compressor drive belt first, following instructions below. Refer
to paragraph 87 for generator drive belt adjustment.
e. Air Compressor Drive Belt Adjustment.
SCREWDRIVER WRENCH, socket, % g-in., with
WRENCH, open-end, Vst-in. extension
WRENCH, open-:end, %-in. WRENCH, socket, s/s-in.
WRENCH, open-end, 3/4-in. WRENCH, socket, 3/4-in.
(1) Remove Left Front Fender and Generator. Refer to para-
graph 87.
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(2) Adjust Compressor Belt.
WRENCH, socket, s/s-in.
Loosen cap screws holding compressor bracket to engine. Slide
bracket up or down to tighten or loosen belt. Adjust so one side of belt
at point halfway between pulleys can be pushed inward, towards other
side, about one inch.
(3) Tighten Cap Screws Holding Bracket.
WRENCH, socket, Vs-in.
Tighten cap screws holding compressor bracket to engine. Make sure
compressor and bracket are square with engine so belt pulley will be
in line.
(4) Install Generator and Fender. Refer to paragraph 87 for in-
stallation of generator and fender and generator belt adjustment.
f. Removal of Dash-Mounted Air Valve.
WRENCH, open-end, %e-in. WRENCH, socket, %^-m.
WRENCH, open-end, s/s-in.
( 1 ) Disconnect Air Lines.
WRENCH, open^end, s/s-in.
Disconnect the three air lines from valve.
(2) Remove Valve.
WRENCH, open-end, %6-in- WRENCH, socket, »/]6-in.
Remove the two bolts holding valve to dash and lift out valve.
g. Installation of Dash-Mounted Air Valve.
WRENCH, open-end, %fi-in. WRENCH, socket, %6-in.
WRENCH, open-end, Vs-in.
( 1 ) Install Valve on Dash.
WRENCH, open-end, %6-in. WRENCH, socket, %6-in.
Hold valve in position against dash and install the two bolts.
(2) Connect Air Lines to Valve.
WRENCH, open-end, %-in.
Connect the three air lines to valve. Start engine and check operation
of valve.
h. Removal of Steering Lever Controlled Air Control Valve.
PLIERS WRENCH, open-end, s/s-in.
WRENCH, open-end, 1/2 -in.
( 1 ) Disconnect Air Lines.
WRENCH, open-end, s/s-in.
Remove floor plate (par. 104 c (2)). Disconnect the air lines at valve.
191
TM 9-787A
103-104
HEAVY TRACTOR Ml
(2) Disconnect Control Link.
PLIERS
Remove cotter pin from pin in yoke and remove yoke pin from air
valve actuating lever.
(3) Remove Valve.
WRENCH, open-end, Va-in.
Remove four cap screws holding valve to bracket on battery support
and lift valve.
i. Installation of Steering Lever Controlled Air Control Valve.
WRENCH, open-end, Va-in. WRENCH, open-end, Vs-in.
WRENCH, open-end, %6-in.
(1) Install Valve.
WRENCH, open-end, Va-in.
Hold valve in position against bracket on battery support and install
the four cap screws.
(2) Connect Air Lines.
WRENCH, open-end, Ys-in.
Connect the air lines to fittings on valves.
(3) Adjust Air Valve Control Rod.
WRENCH, open-end, %6-in.
Connect link rod to the air valve actuating lever, installing pin in
fourth hole from top of the air valve actuating lever. Loosen jam nut
on steering lever control rod and remove pin. Adjust control rod with
clevis (shorten or lengthen rod) to obtain full travel of the air brake
actuating lever when the steering lever brake control is fully depressed.
NOTE: After the air valve adjustment has been made, adjust the electric
brake control rod for full travel of the electric brake control lever. This
is done by means of the adjustable yoke on the control rod and should be
done to obtain full travel of actuating controller lever when control grip
on steering lever is fully depressed. Install cotter pins in yoke pins, and
install floor plate (par. 104 d (5)).
j. Air Lines. All air lines should be inspected periodically to detect
cracked or broken lines or loose connections. Replace broken or missing
tubing clips holding air lines to tractor frame. This is important as these
clips prevent lines from vibrating and breakage which may result.
104. ELECTRrC BRAKES.
a. Controller. The controller is mounted on the inside of the right
rear fender of tractor and is operated by linkage from the steering lever
grip control (fig. 110).
b. Load Control Unit. The load control unit, mounted on the dash,
is a rheostat for regulating the amount of current supplied to the
192
TM 9-787A
104
ELECTRIC AND AIR TRAILER BRAKE CONTROL SYSTEM
RAPD 18021
Figure 1 W— Electric Brake Controller and Air Brake Control Valves
controller. Application of brakes on a light vehicle requires less current
than on those of a heavy vehicle. Turning knob to. left decreases and to
the right increases the braking effect.
c. Removal of Controller.
PLIERS WRENCH, open-end, % g-in.
TAPE, friction WRENCH, open-end, 3/4 -in.
WRENCH, open-end, Ys-in. WRENCH, socket, 9/i6 -in.
( 1 ) Remove Rod prom Power Take-off Shifter Lever.
PLIERS
Remove pin from power take-off shifter lever.
(2) Remove Floor Plate.
WRENCH, open-end, 3/4 -in. WRENCH, socket, %6-in.
WRENCH, open-end, % g-in.
193
TM 9-787A
104
HEAVY TRACTOR Ml
Remove two cap screws holding clutch lever stop to top of floor plate
and transmission cover and remove stop. Remove plate over top of
master clutch inspection cover by removing two cap screws. Remove
two bolts and eight cap screws and remove floor plate. Loosen three bolts
on outside of each fender which hold foot braces. Hold rear of floor plate
higher than front while removing.
(3) Disconnect Control Link.
PLIERS
Remove cotter pin and pin in yoke to disconnect link from lever on
controller.
(4) Remove Wires from Controller.
WRENCH, open-end, Ys-in.
Remove four nuts which hold wires on controller. Tag each wire to
identify it with post from which it was removed. Tape ends of both
wires on front- of controller as they are taken off.
(5) Remove Controller.
' WRENCH, open-end, % e-in. WRENCH, socket, % g-in-
Remove two bolts holding controller to controller bracket and lift
controller out of tractor.
d. Installation of Controller.
PLIERS WRENCH, open-end, %-in.
WRENCH, open-end, %-in. WRENCH, socket, % g-in.
WRENCH, open-end, %c-in.
( 1 ) Install Controller.
WRENCH, open-end, % e-in. WRENCH, socket, % g-in.
Install controller with two bolts through bracket on fender.
(2) Install Wires on Controller.
WRENCH, open-end, %-in.
Place wires on proper posts of controller. If wires are not marked,
refer to schematic drawing of electric brake wiring diagram (fig. 111).
(3) Connect Control Rod.
PLIERS
Connect control rod to lever on controller with pin. Adjust rod by
means of adjustable yoke to obtain full travel of actuating controller
lever when control grip on steering lever is fully depressed. Install
cotter pin in yoke pin.
(4) Install Rod on Power Take-off Shifter Lever.
PLIERS
Install pin in power take-off shifter lever.
(5) Install Floor Plate.
WRENCH, open-end, a/ir,-in. WRENCH, socket, %6-in.
WRENCH, open-end, 3/4 -in.
194
TM 9-787A
104
ELECTRIC AND AIR TRAILER BRAKE CONTROL SYSTEM
Lower floor plate with steering levers through hole in plate. Slip front
end under bracket of foot brace. Install bolts and cap screws in floor
plate and tighten bolts on outside of fenders which hold foot braces.
.Install plate over master clutch inspection cover. Install steering clutch
lever stop.
STARTER SWITCH
LIGHT SWITCH
o
RESISTANCE
TAIL LIGHT
OUTLET SOCKET
^^
LOAD CONTROLLER
GROUND
CONTROLLER
-LER I
STOP LIGHT
RA PD 17501
figure J1 J— Wiring Diagram— Electric Brake Control System
e. Removal of Load Control Unit.
SCREWDRIVER WRENCH, open-end, s/s-in.
TAPE, friction WRENCH, open-end, Y-i g-in.
(1) Remove Knob.
SCREWDRIVER
Loosen small set screw in side of knob and slip knob from shaft.
(2) Remove Load Control Unit from Dash.
WRENCH, open-end, Vs-in.
Remove jam nut from unit and pull load control unit from dash.
Notice position of insulating washers.
(3) Disconnect Wires.
WRENCH, open-end, Vie-m.
Remove two nuts holding wires to unit. Tape end of each wire as
it is removed.
195
TM 9-787A
104
HEAVY TRACTOR Ml
3
O
w
V
in
O
e
w
V
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k
u
I
a
196
TM 9.787A
104
ELECTRIC AND AIR TRAILER BRAKE CONTROL SYSTEM
f. Installation of Load Control Unit.
SCREWDRIVER WRENCH, open-end, s/s-in.
WRENCH, open-end, '/lo-in.
(1) Connect Wires to Unit.
WRENCH, open-end, "Xe-in-
(2) Install Unit in Dash.
WRENCH, open-end, Ys-in.
Insert shaft of unit through dash from back side. Place dial and
insulating washer over shaft and screw on jam nut. Before tightening
nut, be sure insulating washers are in proper position and dial is placed
with numbers at top.
(3) Install Knob.
SCREWDRIVER
Place knob on shaft and tighten set screw. When correctly installed,
arrow on knob will point to "1" on dial when knob is turned all the way
to the left (counterclockwise), and will point to "4" when knob is turned
all the way to right (clockwise).
197
TM 9-787A
105-107
MASTER CLUTCH AND CLUTCH BRAKE
Paragraph
.Description 105
Operation 106
Trouble shooting 107
Clutch adjustment ; 108
Master clutch brake assembly 109
105. DESCRIPTION.
a. The master clutch is an over-center cam engaging type. A screw
thread adjustment between the adjusting ring and back plate provides
the necessary adjustment to assure proper clutch operation. A driven
disk, with friction lining on both sides, is riveted to a splined hub carried
on the master clutch shaft. All other parts of the clutch except the
release mechanism and clutch brake are bolted to the engine flywheel.
106. OPERATION.
a. To engage the clutch, the pressure plate is forced forward against
the driven disk by means of the control lever and linkage. This tightly
clamps the clutch driven disk between the pressure plate and flywheel,
thus transferring power from flywheel to the driven disk, which carries
it to the transmission. As the control lever is pulled all the way back,
the over-center cams snap in to hold the clutch engaged until pressure
on the control lever snaps them out to release the clutch. A flexible
grease tube extends from outside the clutch housing to the release bear-
ing for lubrication of the bearing. The shafts on which the three cams
are mounted have rollers on each end, making operation easier. These
shafts are equipped with pressure gun fittings for lubrication purposes.
107. TROUBLE SHOOTING.
a. Slipping.
Probable Cause Probable Remedy
Improper adjustment. Adjust clutch.
Oily facings. Wash out clutch. Inspect rear
main bearing seal and wick in
crankshaft for excess oil loss.
Worn or glazed facings. Notify ordnance personnel.
Warped pressure plate. Notify ordnance personnel.
198
TM 9-787A
107-108
MASTER CLUTCH AND CLUTCH BRAKE
b. Does Not, Engage."
Probable Cause Probable Remedy
Facing torn off. Notify ordnance personnel.
Release bearing failure. Notify ordnance personnel.
Adjusting lock worked loose. Adjust clutch and inspect locking
lug.
c. Hard to Operate.
Clutch cams dry.
Warped pressure plate.
Throw-out bearing or clutch
sleeve dry.
Linkage worn.
Linkage binding.
Lining torn off.
Lubricate pressure grease fittings
on cam assemblies.
Notify ordnance personnel.
Lubricate the bearing which also
lubricates the sleeve and shaft.
Install new parts and lubricate
with engine oil.
Clean and lubricate.
Notify ordnance personnel.
d. Clutch Disengages When in Operation.
Pressure plate worn in cam guides. Notify ordnance personnel.
Cam blocks worn. Notify ordnance personnel.
Cam shaft rollers and assemblies Notify ordnance personnel,
worn.
e. Noise, Rattles or Squeaks.
Pilot bearing failure.
Release bearing failure.
Worn clutch shaft splines.
f. Clutch Will Not Disengage.
Pilot bearing failure (bearing
"seized").
Notify ordnance personnel.
Notify ordnance personnel.
Notify ordnance personnel.
Notify ordnance personnel.
108. CLUTCH ADJUSTMENT.
a. Engagement of the master clutch when in proper adjustment re-
quires a pull of from 50 to 55 pounds on the control lever when engine
is idling, or from 60 to 65 pounds when engine is stopped. It should
engage with a snap and lever will lock into position with an over-center
action. When this action is not present or when the pull required on the
lever to engage clutch drops to around 30 pounds, it indicates that the
clutch should be adjusted before slippage occurs. These figures assume
that there is no binding in any of the linkage. If the linkage is binding
in any place, those parts or joints should be freed and lubricated before
attempting to obtain the correct adjustment. Do not adjust the clutch
199
TM 9-787A
108
HEAVY TRACTOR Ml
too tightly, as that would result in faster wear on the linkage and make
operation harder. Proceed as follows:
BAR, pry, small WRENCH, socket, y4-in.
WRENCH, socket, "/ig-in.
( 1 ) Remove Clutch Inspection Cover.
WRENCH, socket, % 6-in. WRENCH, socket, y4-in.
Remove section of floor plate over inspection cover by removing two
cap screws. Remove clutch inspection cover by removing four cap
screws.
RA PD 17641
figure 113— Removing Floor Plate Section
(2) Turn Clutch to Adjusting Position. Disengage clutch and
revolve the clutch until the adjusting lock is located near the inspection
hole.
(3) Disengage Adjusting Lock. Hinge adjusting lock back out of
slot in back plate.
(4) Turn Adjusting Ring.
BAR, pry, small
Pry studs on adjusting ring to turn ring. To tighten clutch, turn ad-
justing ring clockwise; to loosen it, turn the ring counterclockwise. Turn
ring in desired direction, a notch at a time, and test pull required on
lever to engage clutch until desired pull is obtained.
200
TM 9-787A
108
MASTER CLUTCH AND CLUTCH BRAKE
KA PD 17638
Figure 114-kemoving Clutch Inspection Cover
Figure 115— Master Clutch Adiusting Lock
201
RA PD 17228
TM 9.787A
108-109
HEAVY TRACTOR Ml
(5) Lock Ring in Place. Engage adjusting lock in notch in back
plate and install inspection cover and section of floor plate.
b. Washing Master Clutch. If master clutch slips due to over-
lubrication of release bearing or oil leaking from engine or transmission
into clutch compartment, washing of the clutch and compartment will
be necessary. Proceed as follows:
( 1 ) Place 1/2 -inch pipe plug in drain hole at left rear of clutch housing.
(2) Remove inspection hole cover and pour about three gallons of
fuel oil or SOLVENT, dry-cleaning, into clutch compartment.
(3) With gear shift lever in neutral position and clutch engaged,
start engine. Run engine for five minutes without disengaging clutch;
then drain dirty fuel oil or SOLVENT, dry-cleaning, out by removing
pipe plug.
(4) Again place pipe plug in drain hole. Pour about three gallons
of fuel oil or SOLVENT, dry-cleaning, into clutch compartment and
operate engine as before. Disengage and engage master clutch several
times while engine is running; then stop engine and drain fuel oil or
SOLVENT, dry-cleaning, from compartment.
(5) Lubricate throw-out bearing thoroughly.
(6) Lubricate clutch mechanism and linkage by splashing about
a quart of OIL, engine, lubricating, SAE 10, against back of clutch assem-
bly and over release assembly linkage. Allow oil to drain from clutch
compartment. NOTE: This must be done with clutch engaged. If
clutch linkage becomes dry and binds, or is hard to operate, it may be
lubricated in this manner.
109. MASTER CLUTCH BRAKE ASSEMBLY.
a. Description. The master clutch brake assembly is a two-piece
casting which is bolted around the clutch shaft. The brake is faced on
the flanged side with brake lining. When the master clutch lever is
pushed forward, the clutch release bearing carrier is forced back against
the clutch brake assembly, which stops the transmission gears and per-
mits easy shifting. The throw-out mechanism should contact the brake
before operator's hand can come in contact with the dash when pushing
lever ahead to disengage clutch and engage clutch brake. The brake
does not require adjusting very often but should at least be adjusted
before clutch lever can hit dash. This can be done at a time when
covers are removed to adjust master clutch.
202
TM 9-787A
109
MASTER CLUTCH AND CLUTCH BRAKE
b. Clutch Brake Adjustment.
PLIERS WRENCH, open-end, % „-in.
RULER or SCALE WRENCH, socket, 2/4 -in.
( 1 ) Remove Locking Wire.
PLIERS
Cut wire running through head of lock screw and around the clutch
shaft.
(2) Loosen Bolts.
WRENCH, open-end, %6-in. WRENCH, socket, y4-in.
Loosen lock screw. Loosen bolts that clamp the two halves of clutch
brake to clutch shaft.
(3) Engage Master Clutch.
(4) Adjust Clearance. Move brake assembly ahead on shaft until
space between clutch throw-out assembly and brake measures 1 14 -inch
to IVs-inch.
(5) Tighten Bolts; Install Wire.
PLIERS WRENCH, socket, 3/4-in.
WRENCH, open-end, %Q-m.
Tighten bolts clamping brake assembly to shaft. Then tighten lock
screw and install lock wire through head of lock screw and around shaft.
203
TM 9-787A
110-112
HEAVY TRACTOR Ml
Section XIX
STEERING CLUTCHES
Paragraph
Description and operation 110
Trouble shooting Ill
Steering clutch adjustment 112
Washing and lubrication 113
110. DESCRIPTION AND OPERATION.
a. The steering clutches are of the multiple disk type with 15 friction
disks and 14 steel disks in each clutch assembly. Power is transmitted
through these clutches from the bevel gear shaft to the final drive pinion
shafts. The steering clutches are released by means of the- two levers
directly in front of operator (fig. 10). When either clutch is released,
the bevel gear shaft turns without driving or supplying power to the
final drive pinion shaft on that side.
111. TROUBLESHOOTING.
a. Steering Clutch Slipping.
Probable Cause Probable Remedy
Improper adjustment. Adjust clutches.
Friction disks worn out. Notify ordnance personnel.
Loss of spring tension. Notify ordnance personnel.
Grease in clutch. Wash clutches.
b. Clutch Will Not Disengage.
Improper adjustment. Adjust clutches.
Throw-out bearing failure. Notify ordnance personnel.
Lower end of throw-out fork out of Notify ordnance personnel.
equalizer in bottom of steering
clutch compartment.
112. STEERING CLUTCH ADJUSTMENT.
a. Check each clutch lever for adjustment separately. Perform the
following steps to check if steering clutch needs adjustment:
(1) Place one end of a ruler or scale against the dash so it projects
horizontally past the top of the steering clutch lever,
(2) Push the lever forward as far as it will go; at this point the
bottom end of the lever strikes a stop on the gear shifter housing and
prevents it from going too far forward.
204
TM 9.787A
112
STEERING CLUTCHES
(3) Pull the lever back until the lost motion is taken up. This can
easily be felt by a definite increase in the pull required to release the
clutch.
(4) Observe the measurement of the distance between the dash and
the top of the lever when it is in its forward position, and also the dis-
tance when the lever is pulled back to the position where the lost motion
is all taken up. The free motion or difference between these two measure-
ments should not be less thon 3 inches and not more than 5V^ inches.
As the steering clutches wear, the free motion of the levers becomes
less. If the free motion of the lever does not come within the limits of
3 inches to SVi inches, then proceed with adjustment.
ADJUSTING SCREW
ADJUSTING
CAPSCREW
BELL CRANK
JAM NUT
RA PD 51350
Figure 116— Steering Clutch Adjustments
b. Adjustment.
RULER or SCALE, 12-in. WRENCH, socket, y4-in.
WRENCH, open-end, ^ifi-in. WRENCH, socket, yg-in., with
(2) extension
WRENCH, open-end, a/^-in.
(2)
( 1 ) Remove Steering Clutch Ventilating Cover.
WRENCH, socket, %.in., with WRENCH, socket, %-in.
extension
Remove seat cushions. Remove four cap screws and remove ventila-
ting cover.
205
TM 9-787A
112
HEAVY TRACTOR Ml
RA PD 17600
Figure 1 17— Adjusting Steering Clutches
(2) Check and Adjust Clearance Between Bell Crank and
Clutch Cover.
SCALE WRENCH, open-end, %6-in.
(2)
Check the clearance between the bell crank and steering clutch cover
when the steering levers are as far forward as they will go. This clear-
ance (A, fig. 116) should be Vs inch. If this clearance is maintained,
there will always be a sufficient amount of clearance between the throw-
out bearings and the shifter plate when the top of the steering levers
and top of throw-out fork have the proper free motion. If there is not
Va inch clearance, proceed as follows to correct the adjustment: Push
the steering clutch levers as far forward as they will go and hold it in
that position. Loosen the jam nut and turn the adjusting cap screw in
until the end of the bell crank is moved away from the bracket Vs inch.
Tighten jam nut. NOTE: This adjustment is very important and it
should be done carefully. If there is no clearance at "A," it is possible
for the clutch throw-out bearings to ride against the shifter plate even
though the steering clutch levers have proper amount of free travel.
206
TM 9-787A
112-113
STEERING CLUTCHES
(3) Check and Adjust Free Travel of Top of Throw-out Fork.
RULER or SCALE, 12-in. WRENCH, open-end, V^-in.
(2)
Measure distance "B" between top of throw-out fork and edge of
cover (steering lever held forward). Then pull steering lever back to
end of its free travel or the point where pressure is felt and disengage-
ment of clutch begins. Hold lever in that position and measure dis-
tance "C" (between top of throw-out fork and edge of cover). This
distance should be % o inch less than distance "B." This ^j g inch free
travel of top of throw-out fork can be obtained by loosening nut on
lock bolt and turning adjusting screw in or out to decrease or increase
the distance "C." When the % e '"ch free travel is obtained, tighten nut
on lock bolt. The steering clutch lever should now have 5 to 5 Vz inches
free travel at top of lever before disengagement of clutch begins.
113. WASHING AND LUBRICATION.
a. Washing Clutches. If grease or oil accumulates in steering clutch
compartments from closed drains and leaks or over-lubrication of throw-
out bearings, slipping of clutches will result. Open drains and wash
clutches and compartments as follows:
(1) Lubricate Throw-out Bearings. Use pressure gun and fill
throw-out bearings with grease.
( 2 ) Install Pipe Plugs in Drain Holes.
(3) Pour Cleaning Fluid into Compartments. Remove steer-
ing clutch inspection covers and pour five gallons of fuel oil into each
compartment.
(4) Wash Compartments. Start engine and run tractor backward
and forward for several minutes without releasing either steering clutch.
Stop tractor and drain compartments.
(5) Wash Clutches. Install drain plugs again and pour same amount
of fuel oil into each compartment. Operate tractor with no load for five
minutes, releasing both steering clutches as often as possible. Drain
compartments.
(6) Lubricate Mechanism. The steering clutch throw-out bearings
and mechanisms should be lubricated after the steering clutches are
washed out,, as all lubricant will have been washed out. Since it is pos-
sible that some fuel oil might drain from the steering clutch compart-
ments into the final drive gear cases during the process of washing, the
final drive gear cases should be drained, flushed, and refilled with new
oil after the steering clutches are washed.
b. Lubrication. The bell crank pivot pins (fig. 17) are provided
with pressure gun grease fittings and should be lubricated every 8 hours
207
TM 9-787A
113
HEAVY TRACTOR Ml
of operation. Flexible grease tubes from the bearings on the throw-out
forks extend through the top of the transmission case, and these bear-
ings should be lubricated every 8 hours through the fittings on these
tubes. Do not use other than a hand gun for lubricating these points,
as over-lubrication may get grease on the steering clutch disks.
208
TM 9-787A
114-115
Section XX
TRACTOR BRAKES
Paragraph
Description 114
Brake adjustment 115
114. DESCRIPTION.
a. The brake system on the tractor consists of lined bands which
encircle the brake drums and are operated by the two foot pedals. The
brakes are used in conjunction with the steering clutch levers for making
short turns. Lever locks are provided to hold the brakes in applied or
locked position for parking purposes.
115. BRAKE ADJUSTMENT.
a. The brake bands are one-piece bands installed with the two ends
of the band towards the rear of the tractor. A post at the front of the
steering clutch and brake compartment of the transmission case engages
a socket on the back of the brake band and supports the band on that
side. Two adjustments are required, one to adjust the lower half of the
band, the other to adjust the upper half.
b. The adjusting nut, shown in figures 118 and 119, controls the
adjustment of the upper band. The adjusting screw, also shown in the
figures 118 and 119, control the adjustment of the lower band. It is very
important that both the adjusting nut and adjusting screw be used when
making adjustment as follows:
SCREWDRIVER, large (2) WRENCH, open-end, 3/4 -in.
(1) Remove Covers from Rear of Transmission Case.
WRENCH, open-end, y4-in.
Remove the four cap screws from each cover and remove the cover.
(2) Always Adjust the Lower Half of Band First.
SCREWDRIVER, large (2)
Pry the adjusting screw lock up off the adjusting screw far enough
to disengage the V-locking notches in the spring and screw and hold in
that position with one screwdriver. Turn the screw to the right or
clockwise to tighten the brake by pushing on the comers of the screw
head with the other screwdriver. This raises the lower half of the band.
Raise the band to the point where it almost touches the drum and
yet can be moved sideways on the drum easily with the hand. About
% 4 -inch clearance is desired. When this is done be sure the V-notches
in the screw head are in a position where the V's in the lock will drop
into them when it is lowered. The cap screw above the adjusting screw
spring should always remain tight. It has no part in adjustments.
209
TM 9-787A
115
HEAVY TRACTOR Ml
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210
TM 9-787A
115
TRACTOR BRAKES
RA PD 17609
Figure 1 19— Adjusting Brakes
(3) Adjust the Upper Half of Band.
WRENCH, open-end, Vt-m.
Turn the adjusting nut to the right (clockwise) to lower or tighten
the upper half of the band, bringing it closer to the drum. This half of
the band should also have 1^4 -inch clearance between it and the drum
(measured at top of drum). Test by moving the band sideways with
the hand.
(4) Test the Free Foot Pedal Travel. Drive tractor forward in
second gear at full throttle and push down on the foot pedal to see
how far the pedal can be depressed. If the pedal cannot be pressed two-
thirds of the way to the floor, the brakes are too tight and will heat.
Back the adjusting screw up one-half turn and the adjusting nut one
full turn. Test again and repeat backing off the adjusting screw and
nut as above until the desired free pedal travel is obtained.
(5) Install Covers.
WRENCH, open-end, y4-in.
Install covers on rear of transmission case with the four cap screws
provided for each cover.
211
TM 9-787A
116-118
HEAVY TRACTOR Ml
Section XXI
FINAL DRIVES
Paragraph
Description 116
Lubrication 117
Sprocket hub bearing adjustment 118
116. DESCRIPTION.
a. The large final drive gear is mounted on a splined hub driven by
a small final drive pinion and shaft. The hub rotates on tapered roller
bearings on the sprocket shaft and the drive sprocket is bolted to a
fiange on the hub. Two seal assemblies in each final drive assembly
guard against the entrance of dirt and water and prevent oil from escap-
ing. Each oil seal assembly consists of two finely machined steel rings,
one turning with sprocket and one held stationary. A spring arrange-
ment holds the two seal rings tightly against each other so that dirt or
oil cannot pass between them, thus forming a seal.
117. LUBRICATION.
a. SAE 90, OIL, transmission, is used to lubricate the final drive
assembly. The oil level should be maintained level with the final drive
filler plug. Inspection should be made after every 8 hours of operation
to see if oil is at this level. The final drive cases should be drained and
refilled with new oil after every 240 hours of operation. The magnetic
drain plug is designed to catch small metal particles that might chip
off or wear off during operation. This plug should be cleaned off and
magnetism tested each time final drive gear cases are drained.
118. SPROCKET HUB BEARING ADJUSTMENT.
a. The sprocket hub bearings should be adjusted periodically. Ad-
justment procedure is as follows:
WRENCH, hexagon, Vi-in. WRENCH, socket, is/ie-in.
WRENCH, open-end, %-in. WRENCH, socket, 1-in.
WRENCH, open-end, 3-in.
( 1 ) Remove End Cover.
WRENCH, socket, 1-in.
Remove two cap screws and take off end cover from isprocket shaft
bracket.
212
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FINAL DRIVES
(2) Remove Sprocket Guard.
WRENCH, socket, %-in. WRENCH, socket, ^Yia-in.
Remove two bolts holding sprocket guard to truck frame and remove
sprocket guard.
(3) Loosen Clamp Screw.
WRENCH, hexagon, Va-in.
Loosen clamp screw in sprocket shaft nut.
RA PD 17658
Figure 1 20 -Loosening Clamp Screw. in Sprocket Shaft Nut
(4) Adjust Bearings.
WRENCH, open-end, 3-in.
Unscrew sprocket shaft nut about 1 inch. Oil threads on axle with
engine oil. Then sc^ew sprocket shaft nut on, until nut touches thrust
washer. Tighten clamp screw just enough to keep sprocket shaft nut
from spreading while it is tightened. Use a 4-foot extension on wrench
and tighten nut until bearings are tight. Back off the sprocket shaft nut
one-sixth turn for bearing clearance, and tighten clamp screw.
(5) Install Sprocket Guard and End Cover.
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HEAVY TRACTOR Ml
RA PD 17659
Figure 121— Adjusting Sproeliet Hub Bearings
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Section XXII
TRACKS AND TRUCK FRAME ASSEMBLY
Paragraph
Description 119
Track release mechanism 120
Truck wheels 121
Track support rollers 122
Removal and installation of pintle drawbar assembly 123
119. DESCRIPTION.
a. The track assembly includes track rails and shoes. The street
plates are accessories installed on tracks to prevent damage to road sur-
faces. The pins and bushings in ti-ack rails are of hardened steel and
are pressed into the track rails. The master pin is a little longer than
the other pins. When necessary to remove track assembly, this pin is
ordinarily removed to split the tracks. The 20-inch track shoes are bolted
to rails with special hardened bolts and street plates are bolted to the
shoes.
b. The truck frame assembly includes the truck frame, track release
mechanism, front idlers, truck wheels, and track support rollers. The
truck wheels, five on each side, carry the weight of the tractor, except
when crossing obstacles, when part of the weight of the tractor may be
supported on the front idlers and sprockets.
120. TRACK RELEASE MECHANISM.
a. Description. The track release mechanism contains a bell crank
and coil spring assembly which allows front idlers to move back to loosen
track and prevent severe strain or breakage if rocks, tree limbs, or other
objects should be caught in the track. The idler brackets are free to slide
on truck frame. Shims are provided between each side of front idler
brackets and track release yoke for track alinement purposes. Adjustment
of tracks is made with an adjusting screw in track release yoke.
b. Track Adjustment.
WRENCH, open-end, '/s-in. WRENCH, socket, i%6-in.
WRENCH, open-end, IVs-in. WRENCH, track adjusting
( 1 ) Loosen Clamp Bolts.
WRENCH, open-end, Vs-in. WRENCH, socket, is/ie-Jn.
Loosen the nuts on clamp bolts in track release yoke.
(2) Adjust Tracks (fig. 123).
WRENCH, track adjusting
Turn the adjusting screw out of the yoke to force the front idler ahead
and tighten the track. Turn it "into the yoke to allow the idler to move
215
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HEAVY TRACTOR Ml
Figure 1 22 -loosening Clamp Bolts on Track Release Yoke
Figure 123-Ad/usting Track
216
TM 9-787A
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TRACKS AND TRUCK FRAME ASSEMBLY
back and loosen the track. Track is properly adjusted when it can be
lifted about 2 inches off support roller with bar (fig. 124). Drive tractor
back and forth a few times after making adjustment. This gives idlers
a chance to move out if brackets are binding on truck frame. Then
check adjustment again with bar. If driving the tractor back and forth
makes no change in track tension, tighten the clamp bolts in track
release yoke.
/- *■ vet*
RA PD I766I
Figure 124— Testing Tracit Adiustment
(3) Check Track Alinement. Observe if inside of track rail is rub-
bing on either flange of front idler. If it is, the idler should be alined.
(4) Aline Front Idler.
WRENCH, open-end, IVs-in. WRENCH, socket, Vs-in.
Remove four cap screws from each guard and lift off idler guards.
Remove two cap screws from each idler bracket holding track release
yoke to brackets. Change correct amount of shims from one side to the
other to aline front idler and give equal clearance between each flange
and inside of rail. Install cap screws in yoke and install idler guards.
121. TRUCK WHEELS.
a. Description. The truck wheels are equipped with tapered roller
bearings and positive oil seals. The positive oil seals prevent dirt or
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HEAVY TRACTOR Ml
water from entering wheels and oil from leaking out. The seal assemblies
consist of fine machined steel rings, one ,held stationary and one turning
with wheel, held so tightly against each other with synthetic rubber
seal boots that oil or dirt cannot pass between them. Three truck wheels
on each side have flanges on outside only, two have double flanges.
1>. Removal.
BLOCK, wood, 8 X 8 in. (2) WRENCH, socket, ^-'ArAn.
WRENCH, open-end, ys-in. WRENCH, socket, IVs-in.
WRENCH, open-end, 1-in. WRENCH, track adjusting
(1) Loosen Tracks.
WRENCH, open-end, Vs-in. WRENCH, track adjusting
WRENCH, socket, i5/ip,-in.
Loosen clamp bolts holding track adjusting screw. Turn screw into
track release yoke until track sags (figs. 122, 123, and 124).
(2) Drive Tractor Up on Blocks.
BLOCK, wood, 8 X 8 in. (2)
Drive tractor forward on first block so that block will be slightly back
of front idler. Then back tractor oiito second block and track will sag to
ground (fig. 125).
(3) Remove Truck Wheel Guard.
WRENCH, open-end, 1-in. WRENCH, socket, 1 Vs-in.
Remove the ten nuts from bolts holding outside truck wheel guard to
truck frame and remove guard.
(4) Remove Truck Wheel Assembly.
WRENCH, open-end, 1-in. WRENCH, socket, IVs-in.
Remove four bolts holding truck wheel brackets to truck frame. Tap
brackets with hammer or pry dowp with small bar. Truck wheel assem-
bly will drop from frame (fig. 125) and can be removed. NOTE: In
some cases, it may be necessary to loosen bolts holding inside truck
wheel guard.
c. Installation.
WRENCH, open-end, ^s-in. WRENCH, socket, IVs-in.
WRENCH, open-end, 1-in. WRENCH, track adjusting
WRENCH, socket, i%6-in.
(1) Install Truck Wheel Assembly in Frame.
WRENCH, open-end, 1-in. WRENCH, socket, 1 Vs-in.
Place truck wheel in position, inserting inside end of truck wheel
through slot in inside truck wheel guard. Hold brackets against frame
and install bolts through frame and brackets. NOTE:^ End of truck
218
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TRACKS AND TRUCK FRAME ASSEMBLY
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219
TM 9.787A
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HEAVY TRACTOR Ml
wheel with plug should be outside. Counting from front of frame, track
wheels 1-3-5 are single-flanged; 2-4 double-flanged.
(2) Install Truck Wheel Guard.
WRENCH, open-end, l-in. WRENCH, socket, IVi-in.
Place guard in position and install bolts.
(3) Drive Tractor Off Blocks and Adjust Tracks (par. 120 b).
WRENCH, open-end, %-in. WRENCH, track adjusting
WRENCH, socket, ^%.e-in.
122. TRACK SUPPORT ROLLERS.
a. Description. The track support rollers and the truck wheels are of
similar construction. They are double-flanged rollers, supported on
brackets on top of the track release housings. Instead of 'having two
brackets on the ends of the shaft as the truck wheels, the track support
roller has one bracket in . the center which is bolted to the support
bracket.
b. RemovaL
JACK WRENCH, socket, l-in.
(1) Raise Track.
JACK
Set jack on track release housing and jack track up, off support roller
far enough to allow removal of roller.
(2) Remove Roller.
WRENCH, socket, l-in.
Remove the two cap screws holding roller to support bracket and lift
oS roller assembly.
c. Installation.
JACK WRENCH, socket, l-in.
( 1 ) Install Roller Assembly.
JACK
With jack on track release housing holding up center of track, install
roller in position and install cap screws and lock washers. Remove jack.
123. REMOVAL AND INSTALLATION OF PINTLE DRAWBAR
ASSEMBLY.
.BAR, pry WRENCH, Vg-in.
BAR, 3-ft WRENCH, is/ie-in.
HAMMER, 2-lb WRENCH, lYie-in.
PLIERS WRENCH, 2 i^-in.
PUNCH, small
220
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9-787A
123
TRACKS AND TRUCK FRAME ASSEMBLY
RA PD 17627
Figure 126— Removing Track Support Roller
WRENCH, V/ie-iti.
a. Procedure.
(1) Remove Drawbar Bolts.
PLIERS
WRENCH, is/i6-in.
Remove cotter pins from bolts holding rear of drawbar to drawbar
plate (pliers). Remove the two bolts (l%a- and 1%6-in. wrenches).
(2) Remove Pivot Pin.
BAR, pry WRENCH, %-in.
Remove cap screw underneath tractor at front end of drawbar (fig.
128) holding pivot pin retainer (%-in. wrench) and remove retainer.
Screw the retainer cap screw into bottom of pivot pin (fig. 129) and pry
pivot pin out (pry bar).
(3) Remove Pintle from Drawbar.
BAR, 3-ft PUNCH, small
HAMMER, 2-lb WRENCH, 2V2-in.
Remove large cotter pin from pintle nut (hammer and punch). Hold
pintle from turning with bar and remove pintle nut (21/2 -in. wrench).
Pull pintle from drawbar. NOTE: If pintle only is to be removed, hold
nut from turning with wrench and turn pintle shaft out of nut with bar.
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HEAVY TRACTOR Ml
RAPD 40662
figure 127— Removing Bolts front Pintle Drawbar
(4) Remove Pintle Drawbar from Tractor.
WRENCH, ys-in.
Remove pivot pin retainer with % x IVi-inch cap screw with lock
washer. Remove pivot pin from recess in transmission case and pull
drawbar from tractor (see fig. 129).
b. Installation of Pintle Drawbar Assembly.
BAR, 3-ft WRENCH, 1%6-in.
PLIERS WRENCH, lyie-in.
WRENCH, ys-in. WRENCk, 2y2-in.
(1) Procedure.
(a) Install Pintle Drawbar'.
WRENCH, ys-in.
Place drawbar in position on plate and insert pivot pin into recess
in transmission case. Install pivot pin retainer with % x 1*4 -inch cap
screw with lock washer (fig. 129).
(b) Install Bolts in Drawbar.
WRENCH, 1%6-in. WRENCH, lyig-in.
Insert the two 1- x 4-inch bolts through rear of drawbar and drawbar
plate, place nuts on bolts, tighten nuts, and install cotter pins through
bolts.
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TRACKS AND TRUCK FRAME ASSEMBLY
RA PD 40637
Figure 128— Removing Retainer Cap Sereyr
RA PO 40636
Figure 1 29 -Removing Pivot Pin
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HEAVY TRACTOR Ml
WRENCH, 2V2-in.
(c) Install Pintle.
BAR, 3-ft
PLIERS
Insert pintle through hole in drawbar and start nut on pintle. Hold
pintle from turning with bar an3 tighten nut (2 1/2 -in. wrench). Install
cotter pin through pintle shaft and nut (pliers).
c. Removal of Pintle Bracket Assembly.
BAR, 3-ft
HAMMER, 2-lb
PUNCH, small
WRENCH, 1%6-in., with long
extension
(1) Procedure.
(a) Remove Upper Pintle.
BAR, 3-ft
HAMMER, 2-lb
WRENCH, l"/ifi-in.
WRENCH, 2y2-in.
PUNCH, small
WRENCH, 2V2-in.
Remove cotter pin from nut (hammer and punch). Hold nut with
2 1/2 -inch wrench and turn shaft pintle out of nut with bar through hook.
Slide pintle out of bracket.
r PINTLE BRACKET
RA PD 5397*
figure 130— Removing PintiB BraekBt
224
TM 9.787A
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TRACKS AND TRUCK FRAME ASSEMBLY
(b) Remove Pintle Bracket.
WRENCH, socket, 1 % ,j-in., WRENCH, 1 '/j ,;-in.
with long extension
Remove four bolts holding lower arms of bracket to drawbar plate and
brace (!%« and I'^u-in. wrenches). Remove the four cap screws holding
upper arms to rear of transmission case (1% i;-^n. wrench with extension.)
and lift off bracket.
d. Installation of Pintle Bracket Assembly.
BAR,3-ft WRENCH, r/i B-in.
PLIERS WRENCH, 21/2-in.
WRENCH, l-'Mfi-in.,
with long extension
(1) Procedure.
(a) Install Bracket.
WRENCH, 15/ic-in., WRENCH, I'/io-in.
with long extension
Set bracket in place. Install four 1- x 3-inch cap screws with lock
washers ' through upper bracket arms and into rear of transmission case
(1%6-in. wrench). Install four bolts with lock washers~through lower
bracket arms and drawbar plate and brace. Install lock washers and nuts
and tighten (1%6 and l^^B^in. wrenches).
(b) Install Pintle
BAR, 3-ft WRENCH, 2 Va-in.
PLIERS
Insert shaft in bracket. Start nut and hold with 2 Va-inch wrench. Insert
bar through hook and turn shaft into nut. Install cotter pin through nut
and shaft and bend ends (pliers).
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TM 9-787A
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HEAVY TRACTOR Ml
Section XXIII
WINCH AND POWER TAKE-OFF
Paragraph
Description 124
Maintenance 125
124. DESCRIPTION.
a. Winch. The winch, with 300 feet of %-inch cable, is mounted
on front of tractor and is driven by the power take-off on rear of tractor.
Drive shafts, supported in ball bearings on side of tractor, run from rear
of tractor to winch gear case* The drum is driven by a worm and gear
through a jaw clutch. This gear reduction makes possible the maximum
pull on cable. The jaw clutch is engaged and disengaged by a control
lever on right fender. The winch drum brake used for controlling drum
is operated by a lever on right fender of tractor. There is also an auto-
matic brake assembly on winch worm shaft. All tractors are being equipped
with winch guards and bumpers to protect the winch from damage by
trees and other obstructions.
b. Power Take-Off. The power take-off is driven by the top trans-
mission shaft. A splined coupling connects transmission shaft to power
take-off shaft. The power take-off is of the reversible type and can turn
winch drum for unwinding cable from drum as well as for winding
cable on drum. The shifter shaft is operated by a control lever ahead
of operator's seat for putting power take-off in winding, unwinding, or
neutral position.
125. MAINTENANCE.
a. The winch gear case and power take-off housing should be kept
filled with lubricant to level of the oil level plugs. End frame bearing and
winch drive shaft bearings and universals should be lubricated after every
eight hours of operation of the winch. The breather cap on top of jjower
take-off housing should be washed periodically in clean fuel oil. Winch
drum brake and automatic winch worm shaft safety brake should be kept
in adjustment. The winch drum brake will require very little adjustment.
If adjustment is required, the brake may be tightened or loosened by
shortening or lengthening the control rod running back to the control lever
on the fender. If automatic winch worm shaft safety brake fails to hold
load when winch is stopped, adjust as follows:
b. Adjustment of Winch Worm Safety Brake.
WRENCH, open-end, y4-in. WRENCH, socket, y4-in.
WRENCH, socket, %e-in.
226
WINCH AND POWER TAKE-OFF
KUWCK i/M^c-ur-r
TM 9-787A
125
RA PD 56396
Figure 131 — View of Power Take-Off Unit
(1) Remove Guard.
WRENCH, open-end, y4-in. WRENCH, socket, 3/4 -in.
Remove three cap screws and two bolts and remove guard.
(2) Remove Cover from Gear Case.
WRENCH, socket, %^-m.
Remove six cap screws and remove cover.
(3) Adjust Brake.
WRENCH, open-end, 3/4 -in.
Refer to figure 132. Tighten nut "A" on brake spring one-half turn,
tighten lock nut and test brake. Tighten another one-half turn if brake
still fails to hold load when winch is stopped. CAUTION : Do not tighten
more than necessary as brake will run hot and lining of brake band will
wear excessively as a result. A clearance of Vs-inch should be main-
tained between nut and shoulder at point "B". This clearance can be
adjusted with the two nuts "C".
(4) Replace Gear Case Cover and Guard.
c. Removal of Cable.
WRENCH, socket, 3/4.in.
227
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125
HEAVY TRACTOR Ml
Figure 132— Adjusting Automatic Winch Brake
RA PD 17669
Figure 133— Removing Cable Clamp
228
TM 9.787A
125
WINCH AND POWER TAKE-OFF
(1) Unreel Cable from Drum. Unreel balance of cable if any is
remaining on drum.
(2) Remove Clamps.
WRENCH, socket, y4-in.
Remove the two nuts and clamp from end of cable and pull end of
cable out through hole in flange of drum.
d. Installation of Cable.
WRENCH, socket, 3/4-in.
(1) Install Cable.
Start end of cable underneath drum, and around the drum to the hole
in flange of drum. Pull about 8-inches of cable through hole.
(2) Install Clamp.
WRENCH, socket, %-in.
Place clamp over cable, install the clamp nuts and tighten, having
about 2 inches of cable extending through clamp.
(3) Wind Cable on Drum. Start engine and wind cable on drum.
Keep cable taut while winding and lay each coil tightly against the one
before it.
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TM 9-787A
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HEAVY TRACTOR Ml
Section XXIV
STORAGE AND SHIPMENT
Paragraph
General 126
Limited storage 127
Placing vehicles in dead storage 128
Removing vehicles from dead storage 129
Preparation for shipment .' 130
Crating 131
Loading 132
126. GENERAL.
a. Selection of Storage Site. All motor vehicles not in use will be
stored in covered or closed buildings whenever practicable. If exterior
storage is necessary, the best available surface will be selected, taking
into consideration, firmness, smoothness and drainage of terrain. Except
when a tactical situation requires concealment, parking under low
hanging limbs of trees will be avoided.
b. Preparation for Storage. Before being stored the vehicle and its
equipment will be thoroughly cleaned, lubricated and inspected, (sees.
IV, V, and VI.) When practicable the vehicles will be promptly repaired
and placed in good operating condition. If repairs can not be made prior
to placing of vehicles in storage, a tag will be attached to the steering
lever specifying the repairs needed, and a written report of these items
will be made to the officer in charge of the vehicles.
c. Spacing of Vehicles in Park. Sufficient space should be allowed
between vehicles to provide accessibility for the routine inspections and
servicing prescribed. Excessive spacing will be avoided in order to con-
serve space.
d. Severe Conditions. Special precautions should be taken for such
severe conditions as: Extreme temperatures, rapid change of tempera-
ture, humid or arid climate, dust, salty spray, corrosive vapors from
nearby industrial plants, or other harmful conditions.
127. LIMITED STORAGE.
a. Definition. Vehicles in limited storage are those temporarily out
of service for less than 30 days, or vehicles that must be ready for
operation on call.
b. Preparation for Limited Storage.
(1) Batteries.
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STORAGE AND SHIPMENT
(a) Batteries that shbw signs of corrosion will be removed and
cleaned as follows: After plugging the vents in the cells, the battery
case will be cleaned with a solution of soda ash or baking soda and
water to neutralize the acid. The concentration of soda ash will be
eight ounces per gallon of water; if baking soda is used, the concentra-
tion will be one pound per gallon of water. After this treatment the
case should be flushed with cold water. Do not use hot water or steam.
Remove plugs from the vents after cleaning. Terminals and cable ends
will be thoroughly cleaned with neutralizing solution and scraped clean
with suitable tool or wire brush.
(b) Terminals of all batteries will be coated with COMPOUND,
rust-preventive, light. Hydrometer readings of each cell will also be
taken. Distilled water or its nearest equivalent will be added to cover
the plates, but not in excess of % inch above separators. If hydro-
meter readings are 1.225 or less, the battery will be charged.
(c) If subzero temperatures are anticipated a higher state of charge,
suitable for the anticipated temperature will be maintained.
(2) Cooling System. If freezing temperature is normally expected
during the storage period, the coolant will be tested with an antifreeze
hydrometer and the proper quantity of antifreeze will be added to
afford protection from freezing at the lowest temperature anticipated
during the storage period, (par. 136). The cooling system will be
inspected for leaks.
(3) Road Tests. The preparation for storage will include a road
test of at least 5 miles after the battery and cooling system service
to check on general condition of the vehicle. Any defects discovered
will be corrected or noted as specified paragraph 126 b.
(4) Engine. The engine will be prepared for storage as follows:
(a) Check the engine oil and replenish, if necessary. Use the recom-
mended grade for temperatures anticipated during storage period,
(sec. IV or XXV).
(b) Drain fuel tank.
(c) Prepare a mixture of 20 percent OIL, lubricating, preservative,
medium, and 80 percent Diesel fuel. Prepare enough of this mixture
to operate the vehicle for 15 minutes. Pour mixture into fuel tank
and run the engine at fast idle for 15 minutes.
(d) Drain the fuel system.
(5) Brakes. Brakes will be released and the tracks chocked. Air
tank will be thoroughly drained by fully opening drain cock. When
no water shows in air stream, close drain cock tightly.
(6) Exterior.
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(a) Rust appearing on any part of the vehicle before storage will be
removed with sandpaper. Painted surfaces will be repainted wherever
necessary to protect the metal.
(b) Exposed polished metal surfaces susceptible to rust will be coated
with OIL, lubricating, preservative, medium.
(c) Winch, cables and chains will be coated with OIL, lubricating,
preservative, medium.
(d) Equipment such as pioneer and truck tools, street plates and fire
extinguishers will remain in place in the vehicle.
(7) Air Compressor. Check oil level, replenish if necessary. Use
the recommended grade for temperatures anticipated during storage
period.
c. Inspections in Limited Storage.
(1) Vehicles in limited storage will be inspected weekly with the
following as a minimum:
(a) Repeat the battery service described in b (1) above. If water
is added when freezing weather is anticipated, recharge the battery
with a portable charger or remove the battery for charging. Do not
attempt to charge the battery by running the engine.
(2) Vehicles in "On call" limited storage for more than 30 days will
receive the following service at monthly intervals, in addition to the
weekly inspection.
(a) Remove the oil filler cap, fill fuel tank and start the engine. Ob-
serve the oil pressure gage. If pressure is registered, shut off the engine
and report this fact to the officer in charge. If no oil pressure is registered,
allow the engine to idle. When the radiator temperature reached 180 F
(if necessary cover the radiator ta obtain this temj)erature) advance
the throttle to a fast idle, not to exceed 800 revolutions per minute and
allow the engine to continue running at this speed and temperature for
30 minutes. After shutting off the engine install the oil filler cap. CAU-
TION: If the cooling system contains a volatile antifreeze, the amount
of liquid will be checked every 5 minutes and more added if necessary.
(b) Repeat the cooling system service outlined in b (2) above.
(c) Repeat the engine service outlined in 6 (4) above.
(d) Repeat to the extent required, the exterior service outlined in
6(6) above.
d. Inspection When Removed from Limited Storage. Upon
removal from storage any item noted by a tag attached to the steering
lever as still needing repair (par. 126 b) will be repaired and the
vehicle will be given a complete monthly maintenance inspection, plus
any repairs which this inspection shows necessary.
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TM 9-787A
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STORAGE AND SHIPMENT
128. PLACING VEHICLES IN DEAD STORAGE.
a. Definition. Vehicles in dead storage are those that will not be
required for service over an indefinite period exceeding 30 days.
b. Engine.
( 1 ) Crankcase. The crankcase will be drained while the engine
is still warm. The oil will be drained from the engine by removing drain
plugs from the crankcase. The oil screen will be removed, cleaned and
reinstalled in the engine. Drain plugs will then be reinstalled in the
engine. Fill crankcase with one-half charge of OIL, lubricating, preserva-
tive, medium. Run engine for 15 minutes at approximately 1,000 revo-
lutions per minute. Leave preservative in crankcase.
(2) Fuel System. The fuel tank will be drained and the fuel system
purged with a mixture prepared as shown below, a quantity of which will
remain in the system when the engine is shut down for storage. Proceed
as follows:
(a) Prepare a mixture of 20 percent OIL, lubricating, preservative,
medium, and 80 percent Diesel fuel.
(b) Drain and clean fuel filters and fuel tanks.
(c) Place approximately two gallons of the fuel oil mixture in tanks
and run engine at normal speed until the two gallons of fuel oil mixture
are nearly exhausted. Leave the remaining oil in the fuel system.
(3) Cylinders.
(a) The cylinder walls, piston heads, and valves will be treated with
OIL, lubricating, preservative, medium.
(b) Remove Injectors. The engine will be cranked by hand until
each piston is placed on bottom center and the inside of that cylinder
will be sprayed through injector opening in head with approximately
one-eighth pint (2 oz) of OIL, lubricating, preservative, medium. Fol-
lowing the above, the crankshaft will be rotated by hand at least two
complete revolutions and the cylinder space above each piston will be
resprayed with approximately one-sixteenth pint (1 oz) of the OIL,
lubricating, preservative, medium. Do not rotate the crankshaft after
this treatment.
(c) Injector. (1) The injectors will be removed and cleaned while
the valves and cylinders are being treated with the preservative.
Clean injectors in SOLVENT, dry-cleaning. Dry thoroughly and dip
in preservative. After the corrosion preventive treatment is completed,
coat the injector holes with the preservative and install the injectors
in the engine. Care must be taken not to damage the injectors. Diesel
engine injectors will remain in the engine during shipping and storage.
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HEAVY TRACTOR Ml
c. Valves and Rocker Arms. Remove rocker arm cover and thor-
oughly clean interior of cover, rocker arms and control rack. Spray with
OIL, lubricating, preservative, medium, while the crankshaft is being
rotated, so that the entire surface of the rocker arms, control rack and
the protruding ends of the valve stems will be coated thoroughly.
Spray the interior of the cover and replace.
d. Cooling System. Drain and flush cooling system, including both
radiator and engine block (par. 74). Compressed air, if available, will
be blown into the outlet passages forcing the moisture down and out
of the inlet passage.
e. Openings. All coolant passage openings, fuel and oil lines, open
connections, or other openings will be coated with preservative.
Threaded openings will be coated with preservative. Plug all openings.
If tapered plugs are used, they will be so constructed that they cannot
be accidently pushed or driven completely into the openings. If plugs
are not available, tubes, or pipes and most other openings can be
sealed satisfactorily by covering with a small piece of oiled or waxed
paper. Gather the ends of the paper around the tube and tie with cord.
The air precleaners can be sealed by covering with a paper bag and
tying a cord around the intake stack.
f. Exterior.
( 1 ) The exterior of the engine will be thoroughly cleaned and dried.
Material used for cleaning must not have a harmful effect on the
exterior of the engine. A coating of COMPOUND, rust-preventive,
light, will be applied to all unpainted steel parts. Rust appearing on
any parts before storage will be removed with sandpaper, and the
metal either painted or lightly coated with rust-preventive, COM-
POUND, light.
(2) Care must be taken to remove COMPOUND, rust-preventive,
light, from exposed rubber and painted parts.
g. Battery.
(1) Remove the battery from the vehicle and service as outlined
in paragraph 127 b ( 1 ).
(2) Place the battery in active stock. Never allow batteries in
stock to become discharged below a hydrometer reading of 1.225. This
will be a proper precaution against freezing in all but the most
severe weather, when a specific gravity of 1.250 will be maintained.
h. Air Compressor. Drain lubricating oil at the same time oil in
engine crankcase is drained. Replace drain plug and fill with one-half
charge of OIL, lubricating, preservative, medium. Run engine for 15
minutes at approximately 1,000 revolutions per minute. Leave pre-
servative in compressor.
234
TM 9.787A
128-129
STORAGE AND SHIPMENT
i. Vehicle. Rust appearing on any part before storage will be
removed with sandpaper. Painted surfaces will be repainted and
unpainted surfaces will be lightly coated with COMPOUND, rust-pre-
ventive, light.
j. Equipment.
(1) Release all brakes and chock the tracks.
(2) Depress clutch pedal and place small block of wood between
clutch control lever and under side of floor board to hold the clutch
out of engagement. The blocks must not be larger than necessary to
make sure the clutch faces are separated.
(3) When vehicles are stored in any open location, remove such
equipment as poineer tools, street plates, chains and fire extinguisher.
Store them separately. When vehicles are stored in closed or locked
buildings, such equipment may remain in place in the vehicles.
k. Inspections.
(1) A tag will be attached to the steering lever on which will be
recorded the date of all inspections, the initials of the inspectors, and
their findings.
(2) Monthly inspections will be made to determine:
(a) Existence and condition of all equipment removed and stored
separately.
(b) That parts and equipment have not been removed without proper
authority.
(c) If the protective measures are effectively preventing deteriora-
tion so that corrective measures can be immediately instituted.
1. Periodic Treatment of Engine and Vehicle. At the expiration of
each 3-month period, the following treatment should be repeated:
(1) Cylinders, (par. b (3)).
(2) Valves, (par. c).
(3) External metal parts, (par. f).
(4) Vehicle, (par. i).
m. Unfavorable Climatic Conditions.
a. For storage in unfavorable climatic conditions, such as might
occur in tropical climates, or near sea water, it may be necessary to
use an additional precaution to prevent corrosion and TOSt. If the
foregoing treatment is inadequate, the engines and vehicles will be
retreated at intervals of 1 month instead of every 3 months.
129. REMOVING VEHICLES FROM DEAD STORAGE.
a. Cooling System. When vehicles are removed from dead storage,
the cooling system will be flushed to remove loose sediment (par.
235
TM 9-787A
129
HEAVY TRACTOR Ml
77 c). New hoses will be installed at this time if required. The cooling
system will then be filled with water. If the temperature is below
freezing, the required amount of antifreeze to afford adequate protec-
tion at the lowest anticipated temperature will be added.
b. Cylinders. Excessive preservative oil above the pistons will be
removed with hand pump, if" available, otherwise remove injectors and
turn the engine over by hand to force out the excess oil.
c. Valves. Rotate the crankshaft through three or four revolutions
by hand and observe the proper operation of valve mechanism. Also
observe that excessive preservative oil or other material is not present
in the cylinder to cause damage due to hydrostatic obstruction when
the engine is turned over. Any valve found to be sticking will have the
stem generously lubricated with penetrating oil or with a 50-50 mix-
ture of kerosene and light lubricating oil, such as OIL, lubricating,
engine, SAE 10. Continue to turn the engine over by hand until all
evidence of sticking valves has been eliminated. If this treatment does
not free the valves, necessary mechanical repairs to free them must be
made before the engine is placed in service.
d. Fuel Tank. Tank will be filled.
e. Battery. Install a fully charged battery.
f. Lubrication. The remainder of vehicle will be thoroughly lubri-
cated before being placed in service (sec. IV). Gear cases will be
drained, flushed and refilled to proper level with the correct lubricant
according to seasonal requirements.
g. Crankcase. Drain old oil and flush the crankcase using one-half
the normal quantity of oil.
h. Inspection. A thorough inspection will be made of the vehicle
at this time. Any repairs which have been ordered at the time the
vehicle was placed in storage, and have not already been performed,
must be accomplished at this time. The following special considerations
will be observed in accomplishing this inspection:
(1) Brakes.
(a) General. It is necessary that the connections of the mechanical
linkage have complete freedom of action. In other words, there must
not be any parts which may be restricted in their action due to drying
out, corrosion, or rusting of movable joints. All clevises, pins, and
movable joints should be free and lubricated carefully. Return springs
should be checked for their full action and useful life. Movement of
brake actuating mechanism will be checked to insure free aption.
Adjust brakes as outlined in paragraph 115.
(2) Sprocket Hub Bearing. When the period of dead storage has
extended over several months, consideration will be given to cleaning
236
TM 9-787A
129-131
STORAGE AND SHIPMENT
and repacking sprocket hub bearings, and replacing all oil seals. This
will be done by ordnance personnel.
(3) Lights. Light reflectors will be cleaned and polished when
necessary. Check for loose or damaged gaskets.
(4) Oil Filters. The oil filter element will be replaced in all
vehicles which have formerly been in service.
i. Starting Engine. If practical, vehicle which is removed from
dead storage will, after the proper preparation for service, be towed
with high gear engaged until the engine starts. See if the engine runs
smoothly. Shut off engine and drain flushing oil while the engine is
still warm. Fill the crankcase with the specified grade and quantity of
lubricating oil.
130. PREPARATION FOR SHIPMENT.
a. After tractor has been used and before it can be crated and shipped,
it must be thoroughly cleaned (par. 44) and inspected. Wash all dirt and
grease from vehicle. Make an inspection of entire vehicle for broken
parts and tighten all loose bolts. Replace worn bolts that cannot be
tightened. Repair or replace broken or missing parts so that tractor
will be ready for operation when it reaches destination. Check tools and
equipment against the equipment list for tractor.
b. If tractor is to be shipped by rail, nothing on tractor need be
removed. If shipment is to be by boat, the tractor must be crated.
Crating requires the removal of the precleaners and extension tubes,
exhaust tail pipe, pintles, and trailer air brake hose connectors. The
cooling system must be drained and battery cables disconnected from
battery terminals.
131. CRATING.
a. Crates. Figure 134 contains specifications and list of material
needed for building crates for this tractor in the event the original
crates have been destroyed and new ones have to be made. Drawings
show construction of crate and how each section is braced.
b. Crating Tractor.
( 1 ) Drive tractor up onto floor of crate so that there is equal clear-
ance on both ends and both sides of floor. Using eight triangular
shaped blocks, nail two blocks at each end of each of the tracks (using
two 60-penny and seven 40-penny nails in each block). Drive these
chocking blocks tightly against tracks before nailing them down. Nail a
block four feet long, four inches high and five inches wide to floor against
inside of each track with six 40-penny nails. These blocks will hold
tractor from shifting in crate. Place banding iron over front pull hook
237
TM 9-787A
131
HEAVY TRACTOR Ml
j-l5--j-25--|-25--|-22+"4-2ai"-|-25''-|-25"-j-l6"-|
TOTAL MATERIAL REQUIRED
BOARD FEET
6" X 8" OAK 240'
2" X 8" Y.P. 460-
2"x4" Y.R 169'
2"x2" Y.P. <S'
l"x6" TG ,YP. 511-
#8 NAILS 8#
#16 NAILS 3-Vi#
#20 NAILS 6->/,#
GROUP
ITEM
NO.
No.
REQ'D.
NAME
STOCK SIZE
MATERIAL
BOARD
FEET
BASE
1
2
4
23./,
192
SKIDS
FLOORING
NAILS
6x8x 173-y,
2x8x 102
#20
RED OAK
Y. P.
232'
267'
6-y<#
SIDES
2
REQ'D.
3
4
5
6
7
8
9
10
4
4
6
4
4
2
2
64
512
92
BRACE
COLUMNS
HEADERS
BRACE
"A" BRACE
BRACE
BRACE
PLANKING
NAILS
NAILS
2 X 4 X 30-y,
2 X 4 X 75.'/,
2x4x173-1/,
2x4x57V,
2x4x113%
2 X 4 X 54
2x4x107-'/,
1 X 6 X 89.1/, T.G.
# 8
#16
Y P.
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
7'
17'
58'
13'
26'
6'
12'
239'
3-%#
2#
AMT. TOT. MAT'L. FOR BLOCKING
16 6x8x18 BLOCKS
6 3 X 5 X 48 BLOCKS
2 BANDIRON 1-V.x49' EA.
24 #60 NAILS 3#
100 #40 NAILS 6#
280 #8 NAILS 2#
40 #16 NAILS 1#
WEIGHT
NET 24,500#
TARE 3,600#
GROSS 28,100#
OVERALL DIMENSIONS
HEIGHT WIDTH LENGTH
92.1/." 103-V," 175"
Cubic Ft. 969
END
11
12
13
14
15
16
17
2
2
2
38
2
4
2
48
304
HEADER
BRACE
BRACE
PLANKING
BRACE
STUD
HEADER
NAILS
NAILS
2x4x 102
2 X 8 X 58-'A
2 X 8 x 56
1 X 6 X 83.1/, T.G.
2x8x 120-V<
2 X 8 X 80-1/4
2x2x91-1/,
#16
#8
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
Y. P.
12'
14'
13-
133'
54'
18'
6'
1#
2V.#
TOP
18
19
20
19
7
3
266
24
PLANKING
BRACE
BRACE
NAILS
NAILS
1 x6x 175 T.G.
2x8 X 102
2 X 8 X 94-%
#8
#16
Y. P.
Y. P.
Y. P.
139'
80'
32'
2#
i/i#
RA PD 17253
Figure 1 34— .Shipping Crate Specifications
238
TM 9-787A
131-132
STORAGE AND SHIPMENT
RA PD 17995
Figure 135— Tractor Blocked to Crate Floor— front View
and nail ends to crate floor. Bore a V2-inch hole in crate floor and in-
stall a long Vi-inch bolt through a hole in drawbar plate and through
the hole bored in floor. The banding iron in front and bolt in rear is
to keep tractor from bouncing on spring.
(2) Fasten pintles and exhaust tail pipe to floor of crate with nails
and banding iron. Place lubricating equipment, precleaners, and tools
in suitable boxes and fasten boxes to floor with blocks around boxes
and banding iron to hold them to floor.
(3) Disconnect battery cables, put gear shift lever in lowest forward
or reverse position and set tractor brakes. Then nail sides, and ends of
crate to crate floor, and install top of crate.
132. LOADING.
a. If tractor is to be shipped by rail, it may be crated and hoisted
on flat car. If this is done, the crate should have blocks nailed to floor
of flat car on all four sides. Nail blocks well with 40-penny nails. If
it is shipped vmcrated, it should be fastened to floor of flat car or box
239
TM 9-787A
132
HEAVY TRACTOR Ml
RA PD 17460
Figure 136— Tractor Blocked to Crate Floor— Rear View
car the same as it is fastened to crate floor, with the exception that the
accessories will be left on tractor. Tools and equipment not carried in
tool boxes should be put in one large box and box fastened to floor of
car. If a flat car ii used, the box should be covered with waterproof
paper.
240
TM 9-787A
132
STORAGE AND SHIPMENT
W"^ •^■wjd
RA PD 179S1
figure 137— Tractor in Crate— Front View
fcS
1. ^v
RA PD,17980
Figure 138— Tractor in Crate— Rear View
241
TM 9-787A
133-134
HEAVY TRACTOR Ml
Section XXV
COLD WEATHER LUBRICATION AND SERVICE
Paragraph
General 133
Fuels for low temperature 134
Preparation and lubrication for continuous operation below OF. 135
Protection of cooling system 136
Mechanical condition of vehicle 137
Cold weather accessories 138
133. GENERAL.
a. Operation of automotive equipment at subzero temperatures pre-
sents problems that demand special precautions and careful extra serv-
icing if poor performance and possible total functional failure is to be
avoided.
1). Extreme care must be exercised whenever a vehicle or parts are
moved from a warm place into subzero temperatures as any moisture
on surfaces will freeze there.
134. FUELS FOR LOW TEMPERATURE.
a. Many fuels suitable for Diesel engines operated in warm weather
contain waxes that congeal at temperatures below F. Congealed wax
clogs fuel strainers and prevents fuel flow to the pump. Fuels for sub-
zero operation are free from these materials. Therefore, Diesel fuel
(U. S. Army Specification 2-102) will be used at low temperatures.
h. If emergency demands procurement of commercial fuel extreme
care will be taken, if practicable, to see that the cloud point is 10 degrees
lower than the lowest atmospheric temperature anticipated. Otherwise
the fuel will not flow to the injectors in quantities sufficient for engine
operation.
c. Water in Diesel fuel will freeze and stop fuel flow in the fuel
pump. The following precautions -should be taken to avoid formation
of ice:
( 1 ) Keep tank full as possible. The more fuel there is in the tank
the less volume of air from which moisture can be condensed.
(2) Be sure that all containers are thoroughly clean, dry, and free
from rust before storing fuel in them.
(3) If possible, after filling or moving a container, allow the fuel
to settle 16 hours before filling vehicle tank with it.
(4) Keep all closures on containers tight to prevent snow, frost,
or other foreign matter entering.
242
TM 9-787A
135-136
COLD WEATHER LUBRICATION AND SERVICE
135. PREPARATION AND LUBRICATION FOR CONTINUOUS
OPERATION BELOW F.
a. Lubrication of this vehicle at temperatures above F is covered
in section IV. The instructions contained in this section are to be fol-
lowed only when temperatures below F prevail.
b. Subzero temperatures affect both metals and lubricants. There-
fore, special attention must be given to lubrication and servicing of equip-
ment when such temperatures are encountered.
c. Shrouds and heaters are supplied and no oil dilution is necessary.
For short shut down periods vehicle should be parked in a sheltered
spot out of the wind if possible. If no shelter is available it will be help-
ful to park so that the vehicle is not facing the wind. For long periods
of shut down as in bivouac, park vehicle in as sheltered a place as
possible.
d. Starting in subzero weather is described in paragraph 12.
e. Transmission and Gear Cases. LUBRICANT, gear, universal,
SAE 80, shall be used for temperatures above —20 F. Below —20 F
LUBRICANT, gear, universal, SAE 80, diluted with the Diesel fuel in
the proportion of one part fuel to six parts of lubricant shall be used.
f. Other lubrication points as track support rollers, are lubricated
with LUBRICANT, gear, universal, SAE 80, above F; no special
attention is required.
( 1 ) Universal and slip joints. Lubricate with GREASE, general pur-
pose. No. 00.
(2) Steering Clutch AND Clutch Throw-out Bearing. Lubricate
with GREASE, general purpose, No. 00. Under conditions of OF and
below it may be necessary to service these bearings more frequently
than for normal operation.
(3) All other places requiring, GREASE, general purpose, shall be
lubricated with OIL, lubricating, engine, SAE 30. CAUTION: When
temperatures below F are no longer anticipated the above bearings
must be lubricated immediately with GREASE, general purpose, proper
seasonal grade.
136. PROTECTION OF COOLING SYSTEM.
a. ETHYLENE GLYCOL (Prestone) is prescribed for use as an
antifreeze solution in vehicle radiators. If ethylene glycol is not avail-
able, other materials may be used. The following table gives three per-
missible materials and the quantity required to protect the cooling
system of this vehicle.
243
TM 9-787A
136-137
HEAVY TRACTOR Ml
Pints, *G.P.A. Pints
Freezing Pints, Ethylene Radiator Denatured
Point Glycol (Prestone) Glycerine Alcohol
10 F
19y2
F
241/2
—10 F
29
—20 F
34
—30 F
39
— 40 F
44
—50 F
44
—60 F
49
—70 F
49
29
241/2
34
29
34
34
39
39
49
49
531/2
—
581/2
—
631/2
*G.P.A. denotes Glycerine Producers Association.
b. Do not use alcohol if the other materials are available for the
temperatures indicated. Denatured alcohol boils at 173 F.
CAUTION: Do not mix antifreeze solutions.
c. The following precautions should be taken before installing the
antifreeze solution.
( 1 ) Thoroughly flush the cooling system. The radiator and the cyl-
inder block should be flushed out separately in order not to transfer
any residue from one unit to the other.
(2) Check the system for leaks; tighten the hose connections and
replace if necessary.
(3) Check thermostats.
(4) Use radiator covers to accelerate and maintain normal engine
operating temperatures. These covers may be improvised locally.
(5) Check the fan belt for adjustment or weakness. Replace the belt
if necessary. Do not use rubber fan belts at temperatures below — 20 F.
Use leather, fiber, or synthetic rubber fan belts.
137. MECHANICAL CONDITION OF VEHICLE.
a. Electrical System.
(1) Wiring. Check and clean all connections, especially the battery
terminals. Care should be taken that no short circuits are present.
(2) Batteries.
(a) The efficiency of batteries decreases sharply ■w(ith decreasing tem-
peratures and becomes practically nil at — 40 F. Do not try to start
the engine with the battery when it has been chilled to temperatures
below — 30 F. See that the battery is always fully charged with the
hydrometer reading between 1.275 and 1.300. A fully charged battery
will not freeze at temperatures likely to be encountered even in arctic
climates, but a fully discharged battery will freeze and rupture at 5 F.
(b) Do not add water to batteries when they have been exposed
to subzero temperatures unless the battery is to be charged immediately
afterward. If water is added and the battery is not put on charge, the
244
TM 9-787A
137-138
COLD WEATHER LUBRICATION AND SERVICE
layer of water will stay at the top and freeze before it gets a chance to
mix with the acid.
(3) Lights. Inspect the lights carefully. Check for short circuits and .
presence of moisture around sockets.
I). Engine.
( 1 ) Keep engine in the best mechanical condition.
(2) Inspect the fuel pump and injectors frequently for wear.
(3) Water pump should have been serviced prior to the advent of
cold weather.
(4) It is necessary to bypass the full flow engine oil filter.
(5) Only in extreme emergencies below 30 F may the fuel filters
be removed if the flow of fuel to the filter is reduced to a point where
engine operation is impaired.
(6) Remove and wa^ air cleaner screens in SOLVENT, dry-clean-
ing, and replace.
c. Chassis.
(1) Brake bands, particularly on new vehicles, have a tendency to
bind when they are very cold. Always have a blowtorch handy to warm
these parts if they bind prior to moving or attempting to move the
vehicle. Parking the vehicle with the brake released will eliminate
most of the binding. Precaution must be taken under these circum-
stances to block the tracks or otherwise prevent movement of the
vehicle.
(2) Inspect the vehicle frequently. The shock resistance of metals
or resistance against breaking is greatly reduced at extremely low tem-
peratures. Operation of vehicles on hard frozen ground causes strain
and jolting which may result in screws breaking or nuts jarring loose.
(3) Disconnect mile meter cable at drive end when operating vehicle
at temperatures of — 30 F and below. Cables often fail to work properly
at these temperatures and sometimes break due to the excessive drag
caused by cold oil. -
138. COLD WEATHER ACCESSORIES.
a. Some cold weather accessories are included in the cold starting
equipment supplied with the vehicle. Items listed below may be used to
supplement this equipment for starting and operating at temperatures
as low as — 40 F.
245
TM 9-787A
138
HEAVY TRACTOR Ml
( 1 ) Insulated battery box with hot water coil in bottom.
(2) Auxiliary battery warming gasoline burning heater.
(3) Insulated battery box with hot air ducts in each compartment.
(4) Foot. warmer heater or cab heater.
(5) Shroud for engine compartment on entire vehicle.
(6) Under chassis heater.
(7) Radiator shutters and louver guards.
(8) Special engine cooling thermostat.
(9) Engine coolant heater.
(10) Straps and hold-downs for cold weather equipment.
(11) Special fuel pump.
246
TM 9-787A
139-140
Section XXV
REFERENCES
Paragraph
Standard nomenclature lists 139
Explanatory publications 140
139. STANDARD NOMENCLATURE LISTS.
a. Cleaning, preserving and lubricating ma-
terials, recoil fluids, special oils, and similar
items of issue SNL K-1
b. Tractor, heavy, Ml w/winch (Allis-Chalmers
HD-10 W) (Diesel) SNL G-98
Current standard nomenclature lists are as tabu-
lated here. An up-to-date list of SNL's is main-
tained in the "Ordnance Publications for
Supply Index" OPSI
140. EXPLANATORY PUBLICATIONS.
a. Automotive Materiel.
b. Cleaning, preserving, lubricating, and weld-
ing materials and similar items issued by the
Ordnance Department TM 9-850
Military motor vehicles AR 850-15
Motor transport FM 25-10
Tractor, heavy Ml (Allis-Chalmers HD-10
W) (Winch, Gar Wood) TM 9-1787A to D
c. Diesels.
Diesel engines TF 9-159
Diesel engines and fuels FS 10-37
Engine of the Diesel tractractor TF 9-171
Power train of the Diesel tractractor TF 9-172
The electrical system of the Diesel tractractor TF 9-169
The fuel system of the Diesel tractractor ... TF 9-170
The track and suspension system of the
Diesel tractractor TF 9^173
247
TM 9-787A
140
HEAVY TRACTOR Ml
d. Inspection and Maintenance.
Echelon system of maintenance TM 10-525
Fire prevention, safety precautions, accidents TM 10-360
Motor transport inspection TM 10-545
e. Miscellaneous.
Automotive electricity TM 10-580
Diesel engines and fuels TM 10-575
Electrical fundamentals TM 1-455
First echelon of maintenance FS 10-53
Inspection of motor vehicles FS 10-58
List of publications for training, including
training film and film strips FM 21-6
Lubrication FS 10-39
Second echelon of maintenance FS 10-54
The internal combustion engine TM 10-570
The motor vehicle driver — first echelon main-
tenance TF 11-558
f . Shipment and Storage.
Loading of mechanized and motorized arniy
equipment on open top railroad equip-
ment—Association of American Railroads
Storage of motor vehicle equipment AR 850-18
248
TM 9-787A
INDEX
A Page No.
Accessories, cold weather 245-246
Adjustment
fan belt (cooling system) 138
master clutch 199-202
master clutch brake assembly. . . . 203
sprocket hub bearings 213-214
steering clutches 205-207
checking 204-205
track release mechanism. . . . 215-217
tractor brakes 209-211
valve clearance 72-73
winch worm safety brake. . . 226-227
Air brakes
air compressor
air lines, inspection and repair. 192
dash-mounted air valve
installation and removal. . . . 191
description 187
drive belt adjustment .... 190-191
installation 189-190
maintenance 187-189
removal 189
steering lever controlled air
control valve
installation 192
removal 191-192
maintenance 58
operation of 28
Air cleaner, lubrication 32
Air compressor
> crankcase capacity 16
storage treatment 234
(See also air compressor under Air
brakes)
Air heater
description 163-164
burner unit
installation 165-166
removal 164-165
operation 20
pump assembly
installation 166-169
removal 166
switch installation and removal. . 169
Air hose couplings, use of 28
Air lines, inspection and repair. . . . 192
Air pressure gage 185
Air system (See Fuel and air system)
Ammeter
description 160—161
installation and removal 161
Antifreeze solutions 243-244
Page No.
Assignment record 49
Automotive materiel, special
precautions for 55
B
Batteries
description 147
installation 151-152
maintenance 149-151
new, preparing for use 18
storage 234-236
trouble shooting 147-149
Belts, fan (cooling system) 138
Blackout light and bulb (See under
Service lights)
Brakes (See specific names)
Camouflage
paint as 51
preserving 52
Capacities of engine components,
data on 16
Care (and preservation) 49
transmission 24
Chart
operation of engine preheater .... 21
use of gear shift levers 24
Chassis of vehicle, cold weather
treatment 245
Chemicals, liquid, removal of . . . 53-54
Cleaning
general 49
materiel affected by gas 53
Climatic conditions, unfavorable,
storage in 235
Clutch brakes, steering 26
Clutch hub and pilot bearing, lubri-
cation 36
Clutches (See Master clutch. Master
clutch brake assembly, and Steer-
ing clutches)
Cold weather lubrication and ser-
vice 242-246
cold weather accessories. . . . 245-246
continuous operation below OF.. 243
cooling system, protection of . 243-244
fuels for low temperature 242
general discussion of 242
mechanical condition of vehicle
chassis 245
electrical system 244-245
engine 245
249
TM 9-787A
HEAVY TRACTOR Ml
C-Cont'd '''»g« N'
Connections for air brake hoses. 28
Controller (See under Electric
brakes )
Controls
use of 27
(See also Operating instructions
and controls)
Cooling system
capacity 1°
description 124
fan assembly
belts 138
description 134
installation 136
trouble shooting 134-135
hoses and pipes 134
maintenance 57
protection of in cold weather 243-244
radiator
description 130
maintenance 131
trouble shooting 130—131
storage treatment 234, 235-236
thermostat
description 132
installation 133-134
removal 132-133
trouble shooting 132
water manifold
description 128
installation 130
removal 129
water pump
description 124-125
installation 126-128
lubrication 37
removal 125-126
trouble shooting 125-126
Crating vehicle for shipment. . . 237-239
Cylinders
number of l^i 67
storage treatment 236
D
Data, tabulated
capacities 16
dimensions of vehicle 12—13
engine 14, 67
general 12
maximum drawbar horsepower. . . 12
maximum drawbar pull 12
performance 13—14
power take-off 16
Page No.
shipping weight 12
steering 14
tracks 14
winch 14
Dead storage
placing vehicles in : 233-235
air compressor 234
battery 234
cooling system 234
definition 233
engine 233
exterior 234
equipment 235
inspections 235
openings 234
periodic treatment of engine and
vehicle 235
rust removal 235
unfavorable climatic conditions 235
valves and rocker arms 234
removing vehicles from 235-237
battery 236
cooling system 235-236
crankcase 236
cylinders 236
fuel tank 236
inspection 236—237
lubrication 236
starting the engine 237
valves 236
Decontamination of materiel affected
by gas 53—54
Definition of dead storage 233
Description
air cleaner 121-122
cooling system
general 124
fan assembly 134
radiator 130
thermostat 132
water manifold 128
water pump 124
electric and air brake control sys-
tem 187
air compressor
187
electric brakes 192-19^
electrical system
air heater 163-164
ammeter 160-161
batteries 147
general 147
generator 152
250
TM 9-787A
INDEX
D— Cont'd Page No.
, Description — Cont'd
electrical system — Cont'd
generator voltage regulator 156-157
hour meter 161-162
light switch 169
panel light 172
service lights 173
starting motor 158
engine 8, 62-66
equipment 8
exhaust manifold and muffler. ... 74
final drives 212
first stage filter assembly 94
fuel pump 106
fuel supply tank 92
general 8
governor 73
hour meter 29
lubrication system
general I39
oil cooler I43
oil filter 141
oil pump 139
master clutch 198
master clutch brake assembly .... 202
mile meter 31
precleaners 121
seat 8
second stage fuel filter 96
steering 8
steering clutches 204
track assembly 215
tractor and engine number 8
tractor brakes 209
transmission 24
truck frame assembly 215
track release mechanism 215
track support rollers 220
truck wheels 217-218
winch and power take-off 8, 226
Dimensions of vehicle 12-13
Direction of rotation 67
Disassembly
first stage filter assembly 95-96
second stage fuel filter 98-99
Drive chain, lubrication 37
Electric and air brake control system
(See Electric brakes and Air
brakes)
Page No.
Electric brakes
controller
installation 194-195
location 192
removal 193-194
load control unit
installation 197
location and use 192-193
removal 195
maintenance S8
operation 28
Electrical system and equipment
air heater 163-169
ammeter 160-161
batteries 147-152
cold weather treatment 244-245
description 147
generator 152-156
generator voltage regulator. . 156-158
hour meter 161-163
light switch 169-172
maintenance 57
panel light 172
service lights 173-174
starting motor 158-160
wiring 178-180
(See under above names for de-
tailed iniormation)
Engaging the winch 27
Engine
cold weather treatment 245
crankcase capacity 16
data 14, 67
description 8, 62-66
exhaust manifold and muffler. . 74-77
governor 73-74
installation in vehicle 85-90
maintenance 57
removal from vehicle 77-84
rocker arm assembly 69-72
starting instructions
temperature 40 F to F.' 20
temperature below F 21-23
when removing vehicle from
storage 237
stopping 24
storage 233, 234
trouble shooting 67-69
valve clearance 72-73
Equalizing injectors 118-120
251
TM 9-787A
HEAVY TRACTOR Ml
E-Cont'd Pog« No.
Equipment
description °
storage
235
(See also Electrical system and
equipment and Tools and equip-
ment)
Ethylene glycol, use of 244-245
Exhaust, loud, cause and remedy. . . 74
Exhaust manifold and muffler
description ''*
installation 76-77
removal 75-75
trouble shooting 68-69, 74
45
16
Fan assembly (See under Cooling
system)
50 hours of operation, inspection
after
Filter, oil (See oil filter under
Lubrication system)
Final drive case capacity
Final drive (s) (assembly)
description 212
lubrication 212
maintenance 58
servicing 33
sprocket hub bearing adjust-
ment 212-214
Firing order 14, 67
First stage fuel filter (See under
Fuel filters)
Fuel and air system
air cleaner
description 121-122
maintenance 122-123
fuel filters
general description of ....... . 93
maintenance 93-94
(See also Fuel filters)
fuel lines and connections. . 120-121
fuel pump
description 106
installation 106-107
maintenance 106
removal 106
fuel supply tank 92
general discussion of 91-92
injectors 107-120
equalizing 118—120
general . 107-109
installation 114-116
252
Page No.
operation 109-110
removal 110—112
testing 112-114
timing 116-117
maintenance 57
precleaners 121
sediment sumps 92-93
installation 93
removal 92-93
Fuel filters
first stage
description 94
disassembly 95-96
installation 96
maintenance 96
reassembly 96
removal 95
second stage
description 96
disassembly 98-99
installation 100-101
maintenance 99-100
reassembly 100
removal 98
servicing 32
third stage
general IPI
installation 105-106
maintenance 105
removal 101-104
Fuel injectors (See injectors under
Fuel and air system)
Fuel lines and connections. . . . 120-121
Fuel pressure gage (See under Gage)
Fuel pump 106-107
Fuel supply tank 92
Fuel tank
capacity 1^
storage treatment 236
Fuels for low temperature operation. 242
185
Gage
air pressure
fuel pressure
description 182-183
installation 183-:184
removal 183
lubricating oil pressure
installation 181-182
removal 181
maintenance 58
mile meter (See Mile meter)
TM 9-787A
INDEX
G— Cont'd Page No.
Gage — Cont'd
temperature
description 184
installation 184-185
removal 184
Gas, materiel affected by 53-55
cleaning S3
decontamination 53-54
protective measures 53
special precautions for automotive
materiel 55
Gear cases, lubrication for operation
below OF 244
Gear shift levers, use of 24-25
chart 24
Generator
belt installation and removal . 155
checks for normal operation 153-154
description and operation 152
installation 154-156
lubrication 33, 37, 152
removal 154
trouble shooting 152-153
Generator voltage regulator
description J56-157
installation 157-158
removal 157
Governor 73-74
Grease fittings, cleaning 49
Guide, lubrication 32', 34-36
H
Headlight and bulb (See under Ser-
vice lights)
Hoses and pipes 134
Hour meter
description 28, 161-162
how to read 29-30
installation 163
removal 162-163
I
Illustrations for supplementary
lubrication 34-36, 37-41
Injectors, fuel (See injectors under
Fuel and air system)
Inspection (s)
air lines 192
general 42
operation
after 50 hours of 45
after 100 hours of 45
during 43
253
Page No.
in deep mud 48
in deep snow 48
in sandy terrain .^ 48
in water 45, 48
prestarting 42-43
vehicle
limited storage 232
new 17
placing in dead storage 235
removing from dead storage 236-237
Instruments, nonelectrical (See Gage)
K
Knocks in engine, cause and remedy 69
Levers, gear shift, use of 24-25
Lighting system (See Light switch
and Panel light)
Lights (See specific names)
Light switch
description 169
installation 170-172
operation 29
removal 169-170
Limited storage (See limited under
Storage and shipment)
Liquid chemicals, removal of . . . 53-54
Load control unit (See under Elec-
tric brakes)
Loading vehicle for shipment . 239-240
"Log Book," use of 49
Lubricating devices, painting 52
Lubricating oil pressure gage
installation 181-182
removal 181
Lubrication (See also Lubrication
system)
air cleaner 32
clutch hub and pilot bearing 36
cold weather (See Cold weather
lubrication and service)
drive chain 36
electrical system
generator 33, 37, 152
starting motor 158
final drive 33, 212
fuel filters 32
guide 32, 34-36
oil filter 32-33
power take-off 33
reports and records 37
starter 37
TM 9-787A
HEAVY TRACTOR Ml
L-Cont'd Page No.
Lubrication — Cont'd
steering clutches 207-208
and master clutch 33
supplementary illustra-
tions 34-36, 37-41
vehicle removed from storage. . . . 236
winch and winch jaw clutch 37
Lubrication system
general discussion of 139
maintenance 57
oil cooler
description 143
installation 146
removal 143-145
oil filter
description 141
installation 142-143
maintenance 142
removal 141-142
servicing 32-33
oil pump
description 139
maintenance 141
M
Maintenance
air cleaner 122
air compressor 187-
batteries 149
cooling system
definitions of operation names. . .
electrical system
engine
final drive assembly
fuel and air system
fuel filters 93
first stage
second stage 99-
third stage
fuel pump
fuel supply tank
lubrication system
oil filter
oil pump
master clutch
miscellaneous duties
nonelectrical instruments (gages)
precleaners
preventive (See Inspection (s) )
steering clutches
tracks and track frame assembly . .
tractor brakes
winch
123
189
151
57
56
57
57
58
57
94
96
100
105
106
92
57
142
141
58
58
58
121
58
58
58
58
254
Page No.
Master clutch
adjustment 199-202
washing 202
description 198
lubrication 33
maintenance' 58
operation 198
trouble shooting 198-199
use of 24
Master clutch brake assembly
adjustment 203
description 202
Materiel affected by gas (See Gas,
materiel affected by)
Metal surfaces, painting 51
Mile meter
description "31, 185-186
how to read 31
installation and removal 185
Motor, starting (See Starting motor)
Muffler, description and trouble
shooting 74
N
Nonelectrical instruments (See Gage)
Number of cylinders 14
Numbers, tractor and engine 8
Oil cups, cleaning 49
Oil filter (See under Lubrication
system )
100 hours of operation, inspection
after 45
Openings, storage treatment of 234
Operating instructions and controls
abnormal conditions 26
batteries, new, preparing for use. 18
engine
starting 18-23
stopping 24
hour meter 29-30
lighting system 29
mile meter 31
new vehicle 18
inspection 17
preparation for use 17-18
parking vehicles 29
power take-oiff 27
steering clutch brakes 26
steering the vehicle 26
TM 9-787A
INDEX
O— Cont'd Page No.
Operating instructions and controls
— Cont'd
transmission 24-25
use of:
master clutch 24
trailer brakes 27-28
winch and controls 27
Operation
air brakes 28
air heater 20
electric brakes 28
engine preheater 21
fuel injectors 109-110
inspections (See operation under
Inspection (s) )
lubrication for below OF 243
master clutch 198
new vehicle 18
Paint (-ing~)
as camouflage 51
preserving 52
general SO
lubricating devices , 52
metal surfaces 51
preparing 50-51
removing 52
Panel light
bulb installation and removal ... 172
description 172
functioning 29
Parking vehicle 29
Performance of vehicle, data on . . 13-14
Pintle drawbar assembly .' 220-225
installation 222-224
pintle bracket assembly
installation 225
removal 224-225
removal 220-222
Pipes, inspection 134
Power take-off
capacity 16
data on 15
engaging for bearing lubrication. . 27
servicing 33
(See also Winch and power take-
off)
Precleaners 121
Preheater, engine 21
Prestarting inspection 42—43
Prestone, use of in cooling system 243-244
Page No.
Preventive maintenance (See In-
spection (s) )
Protective measures for materiel
affected by gas 53
R
Radiator (See under Cooling system)
Reading:
hour meter 29-30
mile meter 31
Rear coupling socket 28
Reassembly:
first stage filter assembly 96
second stage fuel filter 100
Records
assignment and "Log Book" 49
lubrication 37
References for lubrication 32
Repairing wires 180
Reports (See Records)
Rocker arm assembly 69-72
general 69
installation 70-72
removal 69-70
Rotation, direction of 67
Rust removal from vehicle in
storage 235
s
Seat, description 8
Second stage fuel filter (See under
Fuel filters)
Sediment sumps
installation 93
removal 92-93
Serial number of vehicle 8
Service lights
blackout light and bulb
installation 176
removal 174-175
description 173
headlight and bulb
installation 174
removal 173-174
rear lamp assembly
installation 177
removal 176
stop light switch 178
Shipment (See Storage and ship-
ment)
Shipping weight 12
Short circuit 180
Speeds and drawbar pull 13-14
Sprocket hub bearing adj-ustment 213-214
255
TM 9-787A
HEAVY TRACTOR Ml
S— Cont'd Page No.
Starter, lubrication 37
Starting engine when vehicle is re-
moved from storage 237
(See also starting instructions
under Engine)
Starting motor
description 158
installation 160
lubrication 158
removal 158-159
trouble shooting 158
Steering
data 14
description 8
down hill 26
Steering clutch brakes 26
Steering clutches 204-208
adjustment 205-207
checking for 204-205
description and operation 204
lubrication 38, 207-208
maintenance 58
trouble shooting 204
washing 207
Stop light switch 178
Stopping the engine 24
Storage and shipment 230-241
general discussion of 230
shipment,
crating vehicle 237-239
loading vehicle 239-240
preparation for 237
storage
limited 230-232
definition 230
inspections 232
preparation for 230-232
Sumps, sediment (See Sediment
sumps)
Supplementary lubrication
illustrations 34-36, 37-41
Switches (See specific names)
T
Tabulated data (See Data, tabulated)
Take-off, power (See Power take-off)
Temperature control of engine. . . 18-20
Temperature gage (See temperature
under Gage)
Testing fuel injectors 112-114
Thermostat (See under Cooling
system )
Third stage fuel filter (See urider
Fuel filters)
Page No.
Timing injectors 116-117
Tools and equipment
care of 61
list and location of 59-61
Track assembly, description 215
Track release mechanism
adjustment , 215-217
description 215
Track release spring housing capacity 16
Tracks and track frame assembly
data 14
maintenance 58
Track support rollers 220
Tractor and engine numbers 8
Tractor brakes
adjustment 209-211
description 209
maintenance 58
Trailer brakes, use of 27-28
Transmission
care 24 '
description 24;
preparation and lubrication for
operation below OF 243
use of gear shift levers 24-25
chart 24
Transmission case capacity 16
Trouble shooting
cooling system
fan assembly 134-135
radiator 130-131
thermostat 132
water pump 125-126
electrical system
batteries 147-149
generator 152-153
starting motor 158
engine 67-69
exhaust manifold and muffler ... 74
master clutch 198-199
steering clutches 204
Truck frame assembly
description 215
track release mechanism
adjustment 215-217
description 215
track support rollers 220
truck wheels
description 217-218
installation 218-220
removal 218
256
TM 9-787A
INDEX
V Page No.
Valve clearance
adjustment 72-73
general discussion of 72
Valves (and rocker arms), storage
treatment 234, 236
Vibration of engine, excessive, cause
and remedy 67
w
Washing;
master clutch 202
steering clutches 207
Water manifold (See under Cooling
system )
Water pump (See under Cooling
system)
Weight
engine 67
shipping 12
Wheels, truck (See truck wheels
under Truck frame assembly)
Page No.
Winch (See also Winch and power
take-off)
data 16
description 8
engaging 27
lubrication 37
maintenance 58
use of 27
Winch and power take-off
description 226
maintenance 226-229
cable
installation 229
removal 227-229
winch worm safety brake
adjustment 226-227
Winch gear housing capacity 16
Winch jaw clutch, lubrication 37
Winch worm safety brake adjust-
ment 226-227
Wiring 178-180
TA. G. 062.11 (10-23-42)
O. O. 461/26402 O. O. (12-3-42)
LtT GRA WAO 15 Dec. 5, 1836Z J
By order of the Secretary of War:
Official :
J. A. ULIO,
Major General,
The Adjutant General.
G. C. MARSHALL,
Chief ot Staff.
Distribution:
IB4(3), 6(2); IR4 and 6(3); R9(2); IBn4 and 6(3), 9(1);
IC4 and 6(6), 9(4) (For explanation of symbols, see FM 21-6)
THE ARMY
257
*-^'
PUBLICATIONS DEPARTMENT-RABITAN ARSENAL
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